JP2003213894A - Flooring for bathroom, and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide flooring for a bathroom and a manufacturing method of the flooring that can fully exhibit the hydrophilic property of a hydrophilic paint when a paint film of the hydrophilic paint is formed on a base material. <P>SOLUTION: This flooring 10 for the bathroom comprises the base material 11 made of resin, and the paint film 12 formed by applying the hydrophilic paint onto the surface side of the base material 11. The paint film 12 is formed by eliminating or reducing a water repellent substance contained in the hydrophilic paint. <P>COPYRIGHT: (C)2003,JPO

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a bathroom flooring material and a method for producing the same, and more particularly, when a coating film of a hydrophilic paint is formed on a substrate, the hydrophilicity of the hydrophilic paint is sufficiently increased. The present invention relates to a bathroom floor material that can be exhibited and a method for manufacturing the same.

[0002]

2. Description of the Related Art In many cases, a floor material of a bathroom is subjected to a surface treatment so that hot and cold water on the floor material can be dried as quickly as possible. Among them, it is known that a floor coating for a system bath made of a predetermined resin material is subjected to a surface treatment by applying a hydrophilic paint to the surface side of the base material.

[0003]

However, the above-mentioned hydrophilic coating material is composed of a base material containing a large amount of hydrophilic groups and various additives containing a large amount of water-repellent substance, and the coating film immediately after coating has a base material. It has a property of being divided into a hydrophilic layer formed on the material side and a water-repellent layer on the surface side containing a large amount of water-repellent substance. As a result, since the coating film is formed in the state where the water-repellent layer covers the hydrophilic layer, the surface of the floor material is likely to be made water-repellent particularly in the initial stage of use, and the hydrophilicity of the hydrophilic coating material is sufficiently exhibited. There is an inconvenience that you cannot do it.

[0004]

OBJECTS OF THE INVENTION The present invention has been devised by paying attention to such inconvenience, and an object of the invention is to provide a hydrophilic coating film formed on a substrate with a hydrophilic coating film. It is intended to provide a flooring material for a bathroom and a method for manufacturing the flooring material, which are capable of sufficiently exhibiting the property.

[0005]

In order to achieve the above object, the bathroom flooring material according to the present invention is a bathroom flooring material in which a coating film of a hydrophilic paint is formed on the surface side of a predetermined base material. The coating film is formed by removing or reducing the water-repellent substance contained in the hydrophilic coating material. According to such a configuration, since a coating film in which the water-repellent substance contained in the hydrophilic coating material is removed or reduced is formed, more hydrophilic groups in the coating film are exposed. The hydrophilicity of the flooring material can be sufficiently exhibited by the hydrophilic paint.

Further, the bathroom flooring material according to the present invention is a bathroom flooring material in which a coating film of a hydrophilic paint is formed on the surface side of a predetermined base material, and an uneven portion is formed on the surface of the coating film. It is also possible to adopt the configuration of. According to such a configuration,
By making the surface of the coating film uneven, many water-repellent substances present on the surface side are removed, and more hydrophilic groups in the state of being covered with the water-repellent substance are exposed to the surface, resulting in a floor made of hydrophilic paint. The hydrophilicity of the material can be sufficiently exhibited.

Further, the center line surface roughness Ra of the coating film is preferably set to 0.1 μm to 5 μm. As a result, in addition to the above-described chemical hydrophilicity-imparting effect, a physical hydrophilicity-imparting effect due to the shape of the uneven portion can be imparted, and the hydrophilicity of the flooring surface can be further enhanced. It is possible to make it difficult for stains to remain on the uneven portion.
That is, when the center line surface roughness is less than 0.1 μm,
If the above-mentioned physical hydrophilicity-imparting effect cannot be sufficiently obtained and the center line surface roughness exceeds 5 μm, dirt adhering to the floor material surface remains in the uneven portions, and the floor material surface cleanability is improved. Becomes worse. Here, it is preferable to set the center line surface roughness to 0.2 μm to 1 μm, which can further enhance the above-described physical hydrophilicity imparting effect.

Further, in the method for manufacturing a bathroom flooring according to the present invention, after forming a coating film of hydrophilic paint on the surface side of a predetermined base material, the surface side of the coating film is a polishing member or an abrasive. The water-repellent substance contained in the hydrophilic coating material is removed or reduced by polishing with, or an uneven portion is formed on the surface of the coating film. It is possible to achieve the purpose.

In the manufacturing method, it is preferable that a non-woven fabric containing an inorganic abrasive such as aluminum oxide or silicon carbide is used as the polishing member. Here, it is preferable to set the average particle diameter of the inorganic abrasive to 10 μm to 50 μm. If the average particle diameter is less than 10 μm, the above-described physical hydrophilicity-imparting effect cannot be sufficiently obtained, and if the average particle diameter exceeds 50 μm, the cleaning property of the floor material surface deteriorates.

Further, the abrasive in the manufacturing method contains calcite particles, alumina, aluminum hydroxide, silica, or any combination thereof,
After applying the cleaning agent containing the abrasive to the surface of the coating film, by rubbing the applied portion with an organic nonwoven fabric such as nylon or polyester, the water repellent substance is removed or reduced, or the uneven portion is formed. It is preferable to adopt the technique of forming. Thus, a highly hydrophilic floor material can be easily manufactured by wiping the surface of the floor material.

[0011]

BEST MODE FOR CARRYING OUT THE INVENTION A bathroom flooring material according to the present invention is shown in FIG.
And the basic configuration shown in FIG. 2, that is, the resin base material 11 and the front surface side of the base material 11 (the upper surface side in FIGS. 1 and 2).
Coating film 12 formed by applying hydrophilic coating to
And is configured.

The hydrophilic paint has a static contact angle with water of 5
It means a paint capable of forming a coating film 12 having a temperature of 0 degrees or less, and examples thereof include an alkali silicate-containing inorganic paint, a metal alkoxide-containing inorganic paint, an organic-inorganic composite paint, and a surface-hydrophilizing paint. Here, the organic-inorganic composite coating is an organic component such as acrylic, urethane, polyester, or epoxy, and an inorganic component such as silicate containing silicon as a main component, and a terminal reaction such as vinyl group, glycidyl group or methacryloyl group. It is a coating compounded with group-containing alkoxysilanes (silane coupling agents) and the like. The surface hydrophilizing paint is a paint in which a hydrophilic agent having a hydrophilic group or the like is added to the paint to expose hydrophilic groups such as Si-OH groups on the surface to form a hydrophilic structure.

These hydrophilic paints include a main agent containing a hydrophilic group in the molecular skeleton or added with a hydrophilizing agent, a predetermined curing agent, a diluent solvent such as thinner, and various other additives. It is formed by blending.

In the present specification, "hydrophilic group" means -OH, -O-, -NHCO-, -CONH _2- ,
_{-COOH, -SO 3 H, -OSO 3} H, -OPO (O
H) ₂ , —NH ₂ , —NH—, —NR _{2 and the} like are used as a general term.

The diluting solvent is appropriately blended in consideration of the type of resin as a main component in the paint, the dissolving power, the evaporating property, etc., and is an aliphatic / aromatic hydrocarbon, alcohol, ester / ketone. Examples thereof include glycol ethers and the like. Here, as the aliphatic / aromatic hydrocarbon,
Examples thereof include toluene and xylene. Moreover, methanol and n-butanol can be illustrated as alcohols. Further, examples of the ester / ketones include ethyl acetate, butyl acetate, methyl isobutyl ketone, and ethyl 3-ethoxypropinate. Moreover, butyl cellosolve can be illustrated as a glycol ether.

Most of the above-mentioned various additives are made of water-repellent substances having water repellency. For example, defoaming agents (antifoaming agents), wetting and dispersing agents (stabilizers), thixotropic modifiers (antisagging inhibitors) ), A leveling agent, and the like. Examples of the defoaming agent include a defoaming polymer, polysiloxane, and polyether-modified methylalkylpolysiloxane copolymer. Examples of the wetting and dispersing agent include unsaturated polycarboxylic acid polymers, polysiloxane copolymers, polycarboxylic acid alkyl ammonium salts, long-chain polyamine amides, and polar acid ester salts. Furthermore, examples of thixotropic modifiers include urea urethane and polyhydroxycarboxylic acid amides. As a leveling agent,
A silicone type polymer can be illustrated.

When such a hydrophilic coating material is applied to the base material 11, as shown in FIG. 3, a hydrophilic layer 14 containing a hydrophilic group due to the main component is formed on the base material 11 side. A water-repellent layer 15 containing a water-repellent substance by the above-mentioned various additives is laminated on 14.

In the bathroom flooring 10 shown in FIG. 1, the water-repellent layer 15 is removed by polishing the surface side (upper surface side in FIG. 3) from the state of FIG. Membrane 1
2 is configured.

On the other hand, the bathroom flooring 10 shown in FIG.
The hydrophilic layer 14 and the partially cut water-repellent layer 15
To form the coating film 12.

The removal or partial cutting of the water-repellent layer 15 in FIGS. 1 and 2 is performed by applying a hydrophilic coating on the substrate 11 and then rubbing the surface of the water-repellent layer 15 with a predetermined polishing member. Or a cleaning agent such as a cleanser containing an abrasive is rubbed from the surface side of the water-repellent layer 15 using an organic nonwoven fabric such as nylon or polyester. Therefore, minute uneven portions 16 are formed on the surface side of the coating film 12 in FIGS. 1 and 2. In the case of FIG. 1, the water-repellent layer 1
As long as 5 is removed, the surface side of the coating film 12 may be formed into a substantially flat surface without forming the uneven portion 16.

As the polishing member, for example, a material obtained by fixing an inorganic abrasive such as aluminum oxide or silicon carbide to an organic nonwoven fabric such as nylon or polyester using an adhesive of urethane type or phenol type is used. . Here, the average particle size of the inorganic abrasive is 10 μm.
It is preferably set to m to 50 μm.

As the above-mentioned polishing agent, it is preferable to use, for example, a polishing agent containing calcite particles, alumina, aluminum hydroxide, silica, or any combination thereof.

In the present specification, the "average particle size" means the diameter of the particles is di, n1 particles having a diameter d1 and n2 particles having a diameter d2 in a unit weight of powder,
.. When ni particles having a diameter di are present, the arithmetic average diameter (Σdi · ni / Σni) is set as the average particle diameter. Here, in the case of particles that are not perfectly spherical, as shown in FIG. 4, the longest diameter is L when the particles are viewed in a plane, and
When the width in the direction orthogonal to this is B, the plane area of the particles is F, and the volume of each particle is V, each particle diameter Dp is obtained by any of the following expressions (1) to (4). Dp = B ... (1) Dp = √ (4F / π) (equivalent circle diameter, Heywood diameter) ... (2) Dp = V ^1/3 (Andreasen diameter) ... ( 3) Dp = (6V / π) ^1/3 (equivalent sphere diameter or equivalent diameter) ... (4)

[0024]

EXAMPLES Examples of the present invention will be described below together with comparative examples.

Example 1 First, SMC (sheet molding compound) containing various components in the ratios shown in FIG. 5 was used, and the surface temperature was 145 ° C. and the back surface temperature was 130.
Substrate 1 for system bath under the condition that the pressure is 15000 kN and the keeping time is 420 seconds by using the forming die at a temperature of 1 ° C.
No. 1 was formed (hereinafter, this state is referred to as an unpainted wash floor). Next, a hydrophilic paint was applied to the wash floor. Here, the organic-inorganic composite coating was used as the hydrophilic coating, and the unpainted washing floor was degreased with isopropyl alcohol and then spray-coated on the surface. Then, after leaving it at room temperature for about 10 minutes, it was placed in a drying oven at 100 ° C. for 30 minutes to cure the hydrophilic paint. At this time, as shown in FIG. 3, the coating film 12 obtained by curing the hydrophilic coating material was divided into a hydrophilic layer 14 and a water-repellent layer 15 (hereinafter, in this state). The wash floor is called the wash floor before polishing.) The film thickness of the coating film 12 at this time was 30 μm. And this coating film 1
The surface of No. 2 was polished with a predetermined abrasive, and the center line surface roughness Ra of the coating film 12 was set to 0.1 μm.

[Examples 2 to 6] The center line surface roughness Ra of the coating film 12 was changed from that of Example 1 described above. That is, in Example 2, the centerline surface roughness Ra was set to 0.2 μm, while in Example 3, the centerline surface roughness Ra was set to 1 μm. In Example 4, the centerline surface roughness Ra is 5
It was set to μm. Further, in Example 5, the centerline surface roughness Ra was set to 0.05 μm, while in Example 6, the centerline surface roughness Ra was set to 10 μm.

[Embodiment 7] The washing floor before polishing was polished using a polishing member. At this time, as the polishing member, a nylon organic nonwoven fabric obtained by fixing an aluminum oxide inorganic abrasive having an average particle diameter of 10 μm with a urethane adhesive was used.

[Examples 8 to 10] In comparison with Example 7, the washing floor was formed by using the inorganic abrasives in the organic nonwoven fabric having different average particle diameters. That is, in Example 8, the average particle size of the inorganic abrasive was 50 μm, and in Example 9, the average particle size of the inorganic abrasive was 5 μm. Further, in Example 10, the average particle size of the inorganic abrasive was 70 μm.
m.

[Example 11] A cleaning agent containing an abrasive containing calcite particles was applied to the floor before washing, and the surface was polished by rubbing the applied portion with an organic nonwoven fabric made of nylon.

[Comparative Examples 1 and 2] The unpainted washing floor was designated as Comparative Example 1, while the washing floor before polishing was designated as Comparative Example 2.

An experiment for confirming the hydrophilic performance, the drying performance and the cleanability was carried out on each of the washing floors obtained as described above, and the results shown in FIG. 6 were obtained.

Here, in FIG. 6, as an experiment relating to the hydrophilic property, the state immediately after the washing floor was washed with water was visually confirmed. Here, “⊚” represents a very good evaluation (the water film spreads very thinly and the entire surface is sufficiently wet), and “○” represents a good evaluation (the water film spreads thinly. The entire surface is wet). Also, "△"
Indicates a comparatively good evaluation (a state in which a portion where the water film is thinly spread and a portion where the water film is partially repelled are mixed),
“X” represents the evaluation that the expected hydrophilic performance was not obtained (a state where almost the entire surface repels water).

As an experiment relating to the drying performance, the washing floor was rinsed with water, and the water remaining after being left for 12 hours in an environment of 23 ° C. and 50% relative humidity was visually confirmed. Here, “⊚” represents a state where the entire surface is completely dry, and “◯” represents a state where the entire surface is substantially dry. Further, “Δ” indicates a state where the water film partially remains, and “x” indicates a state where the water droplets remain scattered.

Further, as an experiment concerning the cleaning property, JI
S A 5712 (Glass Fiber Reinforced Polyester Washing Bath Bath) Contamination Test (Vaseline: Carbon Black =
Put 1g of 10: 1 contaminant on the cloth and rub it back and forth 5 times each length and width, put it on the watch glass and let it stand for 30 minutes, remove the dirt with a dry cloth, and wipe with 5% soap and water. The residual stain was observed after 20 cycles of wiping. As a result, in the cases of Examples 6 and 10 in which the surface of the coating film 12 was rough, the stains were slightly less likely to be removed than in the other cases.

Therefore, as shown in FIG. 5, it is clear that Examples 1 to 11 can exhibit higher hydrophilicity than Comparative Examples 1 and 2.

In particular, as a result of Examples 5 and 9, when the surface of the coating film 12 becomes finer, hydrophilicity and drying performance are lower than those of the other Examples, while as a result of Examples 6 and 10, the coating film 12 becomes It is clear that when the surface of 12 is rough, the cleanability is inferior to that of the other examples. Therefore, the center line surface roughness Ra of the coating film 12 may be set to 0.1 μm to 5 μm, and in particular, the center line surface roughness Ra is set to 0.2 μm to 1 μm according to the results of Examples 2 and 3. Preferably. In addition, the average particle size of the inorganic abrasive is 10 μm to
It may be set to 50 μm.

[0037]

As described above, according to the present invention,
When a hydrophilic paint is applied to the substrate, the hydrophilic groups contained in the hydrophilic paint are effectively acted on, and the hydrophilicity of the hydrophilic paint is sufficiently exhibited compared to the case where the hydrophilic paint is simply applied. Can be made.

[Brief description of drawings]

FIG. 1 is a schematic sectional view showing a layered structure of a bathroom flooring according to the present invention.

FIG. 2 is a schematic sectional view showing a layer structure of another bathroom flooring according to the present invention.

FIG. 3 is a schematic cross-sectional view showing a layer structure of a washing floor before polishing.

FIG. 4 is a conceptual diagram for explaining an average particle diameter.

5 is a component table of the base material in Example 1. FIG.

FIG. 6 is a chart showing experimental results.

[Explanation of symbols]

10 ... Bathroom flooring material, 11 ... Base material, 12 ... Coating film, 14 ... Hydrophilic layer, 15 ... Water repellent layer, 16 ...
..Rough parts

Claims (7)

[Claims] 1. A bathroom flooring having a hydrophilic coating film formed on the surface side of a predetermined base material, wherein the coating film removes or reduces water repellent substances contained in the hydrophilic coating material. Floor material for bathrooms, which is characterized by being formed as follows. 2. A bathroom flooring material having a hydrophilic coating film formed on the surface side of a predetermined base material, wherein an uneven portion is formed on the surface of the coating film. 3. The center line surface roughness of the coating film is 0.1 μm.
It is set to m to 5 μm.
Or the floor material for a bathroom according to 2. 4. A hydrophilic coating film is formed on a surface of a predetermined base material, and then the surface side of the coating film is polished with a polishing member or an abrasive to give the hydrophilic coating film. A method for producing a flooring material for a bathroom, which comprises removing or reducing contained water-repellent substances or forming irregularities on the surface of a coating film. 5. The method for manufacturing a bathroom flooring according to claim 4, wherein a non-woven fabric containing an inorganic abrasive such as aluminum oxide or silicon carbide is used as the polishing member. 6. The average particle size of the inorganic abrasive is 10 μm.
The method for manufacturing a flooring material for a bathroom according to claim 5, wherein the flooring material is set to m to 50 μm. 7. The abrasive is calcite particles, alumina,
After coating the surface of the coating film with the cleaning agent containing aluminum hydroxide, silica, or any combination thereof, and rubbing the coated portion with an organic nonwoven fabric such as nylon or polyester. 5. The method for manufacturing a bathroom flooring according to claim 4, wherein the water repellent material is removed or reduced, or the uneven portion is formed.