JP2001059290A - Wall panel and unit bathroom - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a wall panel which is sturdy and exellent in antifouling property, heat resistance and has a gloss favorable in durability and a unit bathroom. SOLUTION: A board 4 is fixed to the front face of a frame 5, in a wall panel. The board 4 is constituted of a base material 1, an alkali metal silicate- based undercoat layer 2 formed on the base material, and an acrylic silicone- based surface layer 3 formed on the undercoat layer 2. An acid-ammonium salt-based aqueous solution having pH of 3.5-10.0 is used for the coating film that water soluble alkali metal silicate-based aqueous solution is applied on the base material and appropriately dried. Then, the coating film is washed with water and dried and an acrylic silicon-based surface layer is formed thereon.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a wall panel and a unit bathroom, and more particularly to a wall panel provided with a water-soluble alkali metal silicate coating on the surface thereof, and a unit bath constituted by using the wall panel. It's about the room.

[0002]

2. Description of the Related Art As a wall panel for constructing a wall of a unit room such as a unit bathroom and a unit toilet room, a panel having a board fixed to a frame or a panel having four bent sides of a metal plate is widely used. ing. As this board, an inorganic base material such as an asbestos cement board or a calcium silicate board is used.

[0003] The surface of the base material or the metal plate is painted to make the base material or the metal plate beautiful. In this case, since the organic coating film is flammable and has poor durability, a nonflammable inorganic coating material is often used. In general, however, inorganic coatings are superior to organic coatings in terms of nonflammability and heat resistance, but are inferior in flexibility, gloss, smoothness, and the like. In particular, substrates such as asbestos cement boards and calcium silicate boards have large dimensional changes in expansion and contraction due to changes in air humidity or water absorption and drying, and inorganic coatings have poor flexibility to sufficiently follow the dimensional changes. Therefore, cracks are liable to occur, and the contaminants penetrate and adhere to the cracks, thereby reducing the stain resistance. Furthermore, the occurrence of cracks tends to cause the efflorescence component in the base material to elute on the surface of the coating film to cause the efflorescence phenomenon.

[0004] The inorganic coatings include a heat-curable type and a room temperature-curable type. In general, a heat-curable paint cannot obtain a sufficiently cured film unless it is heated to about 200 to 300 ° C. However, when an asbestos cement plate or a calcium silicate plate is used as a base material, the base material is heated by this heating. There are problems such as deterioration of strength, denaturation, and discoloration. The room temperature curing type hardly deteriorates the substrate, but requires a curing period of about one week or more to obtain a sufficient cured film.

[0005] In order to solve the above-mentioned problems, in addition to the nonflammability and heat resistance of the inorganic coating film, it has the same gloss and smoothness as an organic paint or glass glaze, and is a disadvantage of the inorganic coating film. Japanese Patent No. 14317850 discloses a method for forming an inorganic coating film which can obtain a coating film having excellent flexibility, stain resistance, and efflorescence resistance and does not cause deterioration of a substrate by heating.

[0006] The method of the patent is to apply a water-soluble alkali metal silicate-based aqueous paint containing powder solids selected from fillers, pigments, hardeners, etc. on a mineral base material and dry it appropriately. Then, the silicate-based aqueous solution paint having a powder solid content of less than or less than the undercoat paint is applied and appropriately dried to give a pH value of about 3.5 to about 3.5. This is a method of applying an acid / ammonium salt aqueous solution of 10.0, washing with water, and drying.

[0007]

SUMMARY OF THE INVENTION An object of the present invention is to improve the stain resistance of a coating film on a wall panel having such an alkali metal silicate coating film.

[0008]

A wall panel according to the present invention is a wall panel comprising a board fixed to a frame, the board comprising a plate-like substrate and an alkali metal silicate formed on the substrate. A base layer, and an acrylic silicon-based surface layer formed on the base layer.

Further, the wall panel of the present invention is a wall panel formed by bending four sides of a metal plate, wherein the metal plate has an alkali metal silicate-based undercoat layer formed on the surface thereof, and an undercoat layer on the undercoat layer. And a formed acrylic silicon-based surface layer.

[0010] In such a wall panel, since an undercoat layer made of an inorganic coating film formed on the surface of a board or a metal plate is covered with an acrylic silicon-based surface layer, it is hardly stained. Can be easily removed by washing with water. The acrylic silicon-based surface layer has high hardness, excellent water resistance and heat resistance, has good adhesion to the undercoat layer, and has excellent durability. In addition, since it has a gloss and enters the porous portion of the undercoat layer, even if the surface layer is worn, the acrylic silicon-based portion that has entered the porous portion remains, and the gloss and waterproofness of the coating film are maintained. You.

This acrylic silicon-based surface layer has the advantage that it has good followability to the expansion and contraction of the base material and that cracks are unlikely to occur.

The acrylic silicon-based surface layer preferably has an inorganic antibacterial agent dispersed therein, whereby the antifouling effect can be enhanced.

In the present invention, it is preferable that the undercoat layer has a higher degree of porosity than conventional ones, since the adhesion between the acrylic silicon-based surface layer and the undercoat layer can be further improved.

The unit bathroom of the present invention uses such a wall panel of the present invention, and forms a wall surface which is robust and excellent in stain resistance, heat resistance, durability and aesthetic appearance.

[0015]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Preferred embodiments of the present invention will be described below in detail with reference to the drawings. FIG. 1 is an exploded perspective view of a wall panel according to the embodiment, and FIG. 2 is a partial cross-sectional view of a board of the wall panel according to the embodiment.

As shown in FIG. 1, the wall panel is obtained by fixing a board 4 to a frame 5 with an adhesive. This frame 5 has a longitudinal ridge 5a and a horizontal ridge 5b,
The configuration of this frame is not limited to the illustrated one. The board 4 has an alkali metal silicate-based undercoat layer 2 formed on the surface (front surface) of a plate-shaped substrate 1, and an acrylic silicon-based surface layer 3 formed so as to cover the undercoat layer 2.

As the substrate 1 of the board used in the present invention,
Asbestos cement board, asbestos perlite board, calcium silicate board, asbestos cement calcium silicate board, gypsum board, mortar board, concrete board, pulp cement board,
Wood chip cement board, GRC (glass fiber reinforced cement) board, CFRC (carbon fiber reinforced cement) board,
SFRC (steel fiber reinforced cement) board, ALC
Examples thereof include a board, a rock wool inorganic molded product, and a metal plate.

Although not shown, the wall panel of the present invention may be formed by omitting the frame and bending four sides of a metal plate such as a steel plate, for example, a galvanized steel plate to provide rigidity.

After a primer (for example, a lithium silicate-based primer treating agent) is applied on the substrate 1 or the metal plate as required, an alkali metal silicate-based undercoat layer 2 is formed. This alkali metal silicate-based undercoat layer has a pH value of 3.5 to 10.0 on a coating film formed by applying a water-soluble alkali metal silicate-based aqueous coating material on a substrate and drying it appropriately.
It is preferably formed by applying an aqueous solution of an acid / ammonium salt, washing with water and drying.

The undercoat layer 2 is formed by applying a water-soluble alkali metal silicate-based aqueous solution once or plural times,
It is formed by performing a series of steps of washing with water and drying by applying an ammonium-based aqueous solution once or by repeating a plurality of times. This alkali metal silicate-based aqueous solution coating may or may not contain a powder. When the alkali metal silicate-based aqueous coating material is applied a plurality of times, the powder content of the coating material at the time of the second or subsequent application is set to 1
You may make it less than the number of times or not to contain a powder. In the case of applying the powder three or more times, the powder content may be reduced sequentially, or may be the same each time.

The water-soluble alkali metal silicate-based aqueous solution contains a solid content of a powder such as a curing agent, a filler and a pigment, if necessary.

The water-soluble alkali metal silicate has the general formula M _{2
O · xSiO 2 · yH 2 O} ( where, M an alkali metal belonging to Group I of the periodic table is, x and y are positive numbers.) Is represented by, multivalent the water-soluble alkali metal silicate A modified water-soluble alkali metal silicate modified with a metal compound may be used. Examples of the water-soluble alkali metal silicate include sodium silicate, potassium silicate, lithium silicate, and the like. The value of x is not particularly limited, but 2 to 5 is preferable from the viewpoint of film forming properties, durability, and the like. The value of y is not particularly limited, and may be any range as long as the composition paint finally obtained has an appropriate viscosity or there is no problem in handling the composition. Modified water-soluble alkali metal silicate, magnesium, aluminum, calcium, zinc, oxides, hydroxides, fluorides, carbonates of polyvalent metals such as zirconium in the water-soluble alkali metal silicate,
It is obtained by dissolving one or more compounds such as phosphates, and contributes to improving the water resistance and chemical resistance of the coating film. One of these water-soluble alkali metal silicates or modified water-soluble alkali metal silicates may be used alone, or a mixture of two or more thereof may be used.

In practice, sodium silicate is excellent in film-forming properties, adhesiveness, low cost, and the like, and in the present invention, an excellent inorganic coating film can be obtained by using only one kind of sodium silicate. The content of alkali metal silicate in the paint is preferably at least about 7% by weight, particularly preferably in the range of about 10 to about 60% by weight.

Examples of the curing agent for the water-soluble alkali metal silicate or the modified water-soluble alkali metal silicate include polyvalent metal oxides such as zinc oxide, magnesium oxide and aluminum oxide; and magnesium hydroxide and aluminum hydroxide. Polyvalent metal hydroxides; polyvalent metal carbonates such as zinc carbonate and magnesium carbonate; polyvalent metal phosphates such as magnesium phosphate, aluminum phosphate and zinc phosphate; zinc silicate fluoride, aluminum silicate fluoride and the like Organic compounds such as glyoxal and oxalic acid, and one or more of these curing agents are used. The effective amount of curing agent is
It is about 1% or more, preferably about 3% or more, typically about 5 to 10% or more by weight of the paint.

Examples of the filler include granular materials such as silica stone, alumina and glass powder; flat materials such as clay and mica; and fibrous materials such as asbestos and glass fiber powder.

The pigments include titanium dioxide, red iron oxide, graphite, chrome green, ultramarine, mars violet, cobalt blue, carbon black and the like.

The content of these powders is preferably 60% by weight or less in the paint.

As other additives, known surfactants, dispersants, defoamers, thickeners and the like are added as required.

This alkali metal silicate-based aqueous coating material is applied and dried at a temperature of room temperature to 150 ° C. for about 0.5 to 48 hours to form a coating film. The thickness of this coating film is 20-20
0 μm, particularly preferably about 30 to 100 μm.

An aqueous solution of an acid / ammonium salt is applied to the coating to cure the coating.

The pH value of the aqueous acid / ammonium salt solution generally ranges from about 3.5 to about 10.0, preferably from about 4 to about 9, and more preferably about 4.5. To about 8.5 and typically from about 5 to about 8. The concentration of this acid / ammonium aqueous solution is 0.5 to
About 10% by weight is preferable.

As the acid / ammonium salt aqueous solution,
An aqueous solution of a salt, which is a reaction product or a reaction product mixture of an acid or an acid salt with ammonia or aqueous ammonia or an ammonia compound, is typically referred to as (1) dissolving the acid / ammonium salt in water or (2) It can be prepared by adding an acid and ammonia water or ammonia gas to water. In order to adjust the aqueous solution to a desired pH value, for example, ammonia water, ammonia gas, or the acid may be added to the aqueous solution appropriately. If necessary, appropriate buffers can be added to effectively maintain the desired pH value. The salt component of the acid / ammonium salt aqueous solution may be a mixture of two or more salts.

As the acid component of the acid / ammonium salt aqueous solution, an inorganic acid or an organic acid or an acid salt thereof can be used. As the inorganic acid, phosphoric acid, hydrochloric acid, sulfurous acid, sulfuric acid, nitric acid, aluminum chloride, Aluminum sulfate, 1st
Representative examples include, but are not limited to, aluminum phosphate, monobasic calcium phosphate, aluminum nitrate, and the like, and organic acids include oxalic acid, citric acid, acetic acid, tartaric acid, and the like. In addition, as typical acid / ammonium salts, ammonium phosphate, ammonium sulfate, ammonium nitrate, ammonium chloride, ammonium acetate and the like can be exemplified, but in general, primary, secondary and / or tertiary ammonium phosphates are particularly preferred. .

In order to apply the aqueous solution of acid / ammonium salt to a coating film, the aqueous solution may be poured onto the coating film, sprayed, or immersed in the aqueous solution.

The contact time with the aqueous solution is preferably about 1 to 24 hours, and the temperature at the time of contact is preferably about room temperature to about 60 ° C.

The mechanism by which the coating film is cured by contact with this aqueous acid / ammonium solution is to selectively and forcibly remove the alkali metal in the alkali metal silicate-based coating film with acid ions to cure the coating film. At the same time, it is considered that a part of the acid reacts with a component in the coating film to bring about a curing action. By treating with an aqueous solution of an acid / ammonium salt, the alkali metal in the coating film which becomes a whitening component is removed, so that a coating film having excellent whitening resistance can be obtained.

Thereafter, by pouring or immersing the coating film in water, substances such as unreacted acid and ammonium salt remaining in the coating film and the substrate are removed, and the coating film is dried. Shrinkage causes fine cracks to occur uniformly. The cracks thus generated are fine, and even if dimensional changes such as water absorption expansion and drying shrinkage of the base material and bending occur, the stress is dispersed and absorbed by the uniform cracks,
No large cracks that cause a decrease in stain resistance do not occur.

A washing time of about 1 to 24 hours is sufficient. When washing with water, instead of water, it acts on the remaining ammonium salt or the like to accelerate the removal (for example, decomposition by a chemical reaction) and substantially has no effect on the coating film. The use of a dilute aqueous solution of NaCl or KCl (for example, about 0.1 to 5% by weight) shortens the washing time.

After washing with water, drying is performed to form an acrylic silicon-based surface layer 3 on the alkali metal silicate-based undercoat layer 2.

In the present invention, the undercoat layer 2 thus formed is made to have a high degree of porosity by reducing the water glass content within the range of 10 to 60%, so that the upper acrylic-silicon-based layer is formed. This is preferable because the adhesion between the surface layer 3 and the undercoat layer 2 can be further improved.

In order to form the acrylic silicon-based surface layer 3 on the undercoat layer 2, an acrylic silicon-based aqueous resin coating is applied, dried, and then heated to cure the coating.

As the acrylic silicone paint, a curable silicone acrylic epoxy aqueous resin paint containing a silicon-containing water-soluble acrylic resin as a main component and an epoxy resin as a curing agent is preferable. This paint has high hardness, durability, weather resistance, acid resistance, by cross-linking with polysiloxane oligomer and cross-linking of acrylic resin / epoxy resin.
Produces a coating film with excellent alkali resistance, heat resistance and solvent resistance. In addition, in a normal case, the drying condition is 60 to 90 ° C.
For about 10 to 60 minutes, and the heating condition is preferably about 0.1 to 2 hours at 100 to 150 ° C.

The acrylic silicon-based surface layer 3
It is preferable to disperse an inorganic antibacterial agent, whereby the antifouling effect can be enhanced.

As the inorganic antibacterial agent, an antibacterial agent in which an antibacterial component such as silver, silver oxide, or a silver complex salt is supported on a carrier such as zeolite, calcium phosphate, zirconium phosphate, amorphous silicon oxide, or titania can be used. The content in the acrylic silicon-based surface layer is preferably set to 0.01 to 3.0% by weight.

The thickness of the acrylic silicon-based surface layer made of the acrylic silicon-based coating film is preferably about 20 to 200 μm, and more preferably about 30 to 100 μm.

The unit bathroom of the present invention is constructed according to a conventional method using such a wall panel of the present invention.

[0047]

EXAMPLES Example 1 (1) Preparation of paint For the undercoat paint, the following preparations were mixed except for water glass with a pot mill for 24 hours, water glass was added thereto, and the mixture was stirred with a screw for 15 minutes and adjusted. did.

<Preparation of undercoat paint> Aqueous sodium silicate solution (40% by weight) 30 [parts by weight] Pigment 8 [parts by weight] Zinc oxide 8 [parts by weight] Silica powder 18 [parts by weight] Sodium pyrophosphate 0.8 [parts by weight] Parts) Aerosil 0.2 [parts by weight] Water 35 [parts by weight] (2) Application of undercoat paint After applying a lithium silicate primer treatment agent to a calcium silicate plate (thickness: 3 mm), the dry film thickness is reduced by air spray. Paint to a thickness of about 50μm, 130 ℃
For 3 hours. This is placed in an aqueous solution of ammonium phosphate at 30 ° C. (2.5% ammonium monophosphate and 2.5% ammonium phosphate, pH 6.5).
8 hours, immersed in water for 12 hours, washed with water
Dried at 0 ° C.

(3) Formation of Surface Layer Next, an aqueous acrylic silicone epoxy resin paint is applied, dried at 60 ° C. for 20 minutes, and then heated at 140 ° C. for 30 minutes.
An acrylic silicon epoxy resin film having a thickness of 50 μm was formed.

The board on which the coating film was formed in this manner was bonded to a frame as shown in FIG. 1 to obtain a wall panel.

Examples 2 and 3 A coating film was formed on a calcium silicate board in the same manner as in Example 1 except that the preparation of the undercoat paint was as follows.
Wall panels were manufactured.

<Preparation of Undercoat Paint of Example 2> Aqueous solution of sodium silicate (40% by weight) 30 [parts by weight] Pigment (titanium white) 7 [parts by weight] Zinc oxide 7 [parts by weight] Silica powder 15 [parts by weight] Sodium pyrophosphate 0.8 [parts by weight] Aerosol 0.2 [parts by weight] Water 30 [parts by weight] <Formulation of undercoat paint of Example 3> Sodium silicate aqueous solution (40% by weight) 30 [parts by weight] Pigment (titanium) White) 6 [parts by weight] zinc oxide 6 [parts by weight] silica powder 14.5 [parts by weight] sodium pyrophosphate 0.8 [parts by weight] aerosol 0.2 [parts by weight] water 27.5 [parts by weight] Example 4 A calcium silicate film was prepared in the same manner as in Example 1 except that a surface layer was formed using a mixture of an acrylic silicone epoxy-based aqueous resin paint and a silver-supported zeolite-based antibacterial agent in an amount of 1.0% by weight. The coating film was formed on a de to produce a wall panel.

Comparative Example 1 A coating film was formed on a calcium silicate board in the same manner as in Example 1 except that the acrylic silicon-based surface layer was not formed, and a wall panel was manufactured.

The stain resistance of the coating film thus formed,
Table 1 shows the results of examining the heat resistance, waterproofness, gloss, and hardness.

The stain resistance was determined by using carbon black of 10%.
Weight percent mixed petroleum jelly, left for 1 day, and examined by wiping with gauze soaked in soapy water.
The water resistance was measured by measuring the water permeability according to JIS Z5400, and the hardness was measured by pencil hardness after being kept in an atmosphere of 0 ° C. for 30 minutes. Gloss is visual judgment of appearance.

Similar results were obtained with a galvanized steel wall panel instead of a wall panel having a calcium silicate board.

[0057]

[Table 1]

[0058]

As is clear from the above Examples and Comparative Examples, according to the present invention, it is robust, excellent in stain resistance and heat resistance,
Provided is a coated wall panel and a unit bathroom having good durability and gloss.

[Brief description of the drawings]

FIG. 1 is an exploded perspective view of a wall panel according to an embodiment.

FIG. 2 is a partial cross-sectional view of the board of the wall panel according to the embodiment.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Base material 2 Undercoat layer 3 Surface layer 4 Board 5 Frame

──────────────────────────────────────────────────の Continued on the front page (51) Int.Cl. ⁷ Identification symbol FI Theme coat ゛ (Reference) E04C 2/08 E04C 2/08 B 2/38 2/38 J E04H 1/12 301 E04H 1/12 301 F Terms (reference) 2E025 AA02 AA13 AA23 BA01 BB05 BC01 2E162 CA01 CA04 CA06 CA07 CA12 CA13 CA16 CA21 CA35 CB01 EA11 FA14 4D075 AE15 CA18 CA34 CA45 CB04 DC02 DC38 EA06 EB02 EB42

Claims (5)

[Claims] 1. A wall panel comprising a board fixed to a frame, the board having a plate-like base material, an alkali metal silicate-based undercoat layer formed on the base material, and a base layer formed on the undercoat layer. A wall panel comprising: an acrylic silicon-based surface layer. 2. A wall panel formed by bending four sides of a metal plate, wherein the metal plate has an alkali metal silicate-based undercoat layer formed on its surface and an acrylic silicon-based surface formed on the undercoat layer. And a wall panel. 3. The coating according to claim 1 or 2, wherein the undercoat layer has a pH value of from 3.5 to a coating film formed by applying and drying a water-soluble alkali metal silicate-based aqueous coating material on a substrate.
A wall panel formed by applying an acid / ammonium salt aqueous solution of 10.0, washing with water, and drying. 4. The wall panel according to claim 1, wherein an inorganic antibacterial agent is dispersed in the acrylic silicon-based surface layer. 5. A unit bathroom using the wall panel according to any one of claims 1 to 4.