JP2006334525A - Method for forming pattern - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for forming a pattern, by which the pattern to be formed has a high degree of freedom and a novel unevenly-patterned plane is obtained and which contributes to the reduction of waste. <P>SOLUTION: A coating material, which contains a water-soluble resin and a granular substance of 30-80 wt% as essential components and has 50-95 wt% solid content, 50-1,500 Pa-s viscosity and ≥3.0 thixotropy index, is applied to a base material to form a coating film having 0.5-15 mm average thickness. An uneven pattern is formed by pressing a pressing tool having the width equal to or larger than the half of the average thickness of the coating film to the formed coating film before the coating material is dried. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a pattern forming method for building interior and exterior surfaces.

  Conventionally, a method of forming various uneven patterns by painting on the interior / exterior surface of a building has been proposed. For example, after applying a joint material or a pattern made of resin foam or the like to the surface to be coated, after applying a finish coating material containing a binder such as a synthetic resin emulsion and a coloring material or an aggregate, There is a method of removing the joint material (Patent Document 1, etc.). In such a method, it is possible to form a grid-like joint pattern such as ceramic tile-like or brick-like.

  However, in the construction method described in Patent Document 1 or the like, when using joint materials, the pattern to be formed is limited to those based on straight lines, and when using pattern paper, the determined shape is repeated. The degree of freedom of the pattern is limited. In addition, in the construction method described in Patent Document 1 and the like, joint materials and paper patterns that have been used once are difficult to reuse, and therefore must be discarded, which is not so preferable from the viewpoint of waste reduction. Absent.

Japanese Patent Laid-Open No. 10-266517

  The present invention has been made in view of the above problems, and proposes a pattern forming method that has a high degree of freedom in the pattern to be formed, can provide a novel uneven pattern surface, and can contribute to waste reduction. It is for the purpose.

  As a result of intensive studies to achieve the above object, the present inventor has conceived a method for forming a pattern using a specific pressing tool on the undried coating film after coating a specific coating material, and the present invention. It came to complete.

That is, the present invention has the following features.
1. An aqueous resin and granular material are essential components, and the granular material is contained in the coating material in an amount of 30 to 80% by weight, the solid content of the coating material is 50 to 95% by weight, the viscosity is 50 to 1500 Pa · s, and the thixotropic index. Is applied to the base material so that the average film thickness is 0.5 to 15 mm,
A pattern forming method characterized in that, while the coating material is undried, the coating film is pressed using a pressing tool having a width of 0.5 times or more of the average film thickness of the coating material to form an uneven pattern.

  In the present invention, the degree of freedom of the pattern to be formed is high, and a novel uneven pattern surface can be obtained. Furthermore, unlike the conventional method, the present invention does not use joint materials, and therefore can contribute to waste reduction.

Specifically, in the present invention, a coating material having a specific powder structure, coating material solid content, and viscosity is used, and a pressing tool having a specific width is used for an undried coating film of the coating material. Press the coating. According to such a method, first, a concave portion corresponding to the shape of the pressing tool is formed at the time of pressing, and the coating material around the pressing portion is appropriately raised. When the pressing tool is pulled away from the coating material, the coating material is unlikely to adhere to the pressing tool, and the shape of the coating film obtained by pressing does not collapse, and the shape is maintained even after pressing. Therefore, the boundary between the concave portion (pressing portion) and the convex portion (non-pressing portion) becomes clear, and the uneven pattern appears sharply.
In the present invention, a novel concavo-convex pattern surface that has not existed in the past can be obtained by appropriately setting the shape of the pressing tool or by variously changing the pressing pattern.

  Hereinafter, the best mode for carrying out the present invention will be described.

  The coating method of the present invention is useful mainly for the interior and exterior of buildings, and can be applied to the surfaces of various base materials constituting internal and external walls, ceilings, floors and the like. Specifically, as the base material, for example, natural base material, wood base material such as plywood, gypsum board, concrete, mortar, fiber mixed cement board, cement calcium silicate board, slag cement perlite board, asbestos cement board, ALC board, A siding board, an extrusion molding board, a steel plate, a plastic board, etc. are mentioned. The surface of these base materials may have been subjected to some surface treatment (for example, putty, sealer, surfacer, filler, etc.), or may already have a coating film formed thereon or may have wallpaper applied thereto.

  In the present invention, a coating material shown below is first applied to the base material as described above.

  The coating material used in the present invention contains an aqueous resin and powder as essential components. Among these, the aqueous resin acts as a binder, and a water-dispersible resin and / or a water-soluble resin can be used. Examples of the resin include acrylic resin, urethane resin, vinyl acetate resin, silicon resin, fluorine resin, ethylene resin, polyester resin, alkyd resin, vinyl chloride resin, epoxy resin, acrylic / vinyl acetate resin, acrylic / urethane resin , Acrylic / silicone resin, polyvinyl alcohol, cellulose derivatives and the like, and one or more of these can be used.

  Such an aqueous resin may have a property of causing a crosslinking reaction when a coating film is formed. By using the cross-linking reactive aqueous resin, the physical properties of the coating such as water resistance can be enhanced. Specific examples of the crosslinking reaction include carboxyl group and metal ion, carboxyl group and carbodiimide group, carboxyl group and epoxy group, carboxyl group and aziridine group, carboxyl group and oxazoline group, hydroxyl group and isocyanate group, carbonyl group and hydrazide group, A combination of an epoxy group and a hydrazide group, an epoxy group and an amino group, and the like can be given.

  Examples of the granular material include, for example, cryolite, kaolin, clay, porcelain clay, china clay, diatomaceous earth, talc, barite powder, quartz sand, gravel, glass beads, resin beads, metal particles, or rocks, glass, ceramics, shells, grilled Examples include aggregates such as aggregates, concrete, mortar, plastic, rubber and other crushed products. Colored ones can also be used.

  In addition, coloring pigments, extender pigments, and hollow particles that can be normally used for coating materials can also be used as powders.

  Examples of the color pigment include titanium oxide, zinc oxide, carbon black, ferric oxide (bengala), yellow iron oxide, iron oxide, silicon oxide, ultramarine, cobalt green, magnesium oxide, zirconium oxide, yttrium oxide, and indium oxide. Inorganic pigments such as alumina, azo, naphthol, pyrazolone, anthraquinone, perylene, quinacridone, disazo, isoindolinone, benzimidazole, phthalocyanine, quinophthalone, etc. Examples thereof include pigments, aluminum pigments and fluorescent pigments.

  Examples of extender pigments include heavy calcium carbonate, calcium carbonate, light calcium carbonate, barium sulfate, clay, kaolin, porcelain clay, china clay, talc, precipitated barium sulfate, barium carbonate, white carbon, diatomaceous earth, and the like. .

  The ratio of the granular material in the coating material is usually 30 to 80% by weight, preferably 40 to 80% by weight, and more preferably 50 to 75% by weight in the coating material. When the mixing amount of the granular material in the coating material is less than 30% by weight, the coating material is easily caught on the pressing tool, and the coating material is liable to sag. It becomes difficult to form the recess. When there are more than 80 weight% of a granular material, the applicability | paintability to a base material, adhesiveness, etc. become easy to be impaired.

  About such a granular material, 30% by weight or more (preferably 40% by weight or more, more preferably 50% by weight or more) has a particle diameter of 1 μm or more (preferably 10 μm or more, more preferably 50 μm or more). It is desirable to adjust the particle size. By adjusting the particle size, a sharp uneven pattern can be obtained with certainty. In addition, the particle diameter of a granular material is a value obtained by sieving using a metal mesh sieve defined in JIS Z8801-1: 2000.

  The coating material in the present invention can be obtained by uniformly mixing the above-described components by a conventional method. The mixing ratio of the aqueous resin and the granular material may be appropriately set within a range in which the amount of the granular material satisfies the above-mentioned conditions. Usually, the granular material is 200 to 2000 with respect to 100 parts by weight of the solid content of the aqueous resin. What is necessary is just to set it as a weight part (preferably 300-1500 weight part). In the coating material in the present invention, since a transparent binder is used, various hues can be expressed by using colored aggregates and / or colored pigments as the powder particles.

  In the coating material according to the present invention, a thickener, a leveling agent, a wetting agent, a plasticizer, a film-forming aid, an antifreezing agent, a pH adjusting agent, an antiseptic agent, an antifungal agent, an anti-algae agent and an antibacterial agent are used as necessary. Various additives such as an agent, a dispersant, an antifoaming agent, a fiber, an adsorbent, an ultraviolet absorber, an antioxidant, a catalyst, and a crosslinking agent can be mixed. Moreover, water can also be mixed suitably.

  The solid content of the coating material is usually 50 to 95% by weight (preferably 60 to 92% by weight, more preferably 65 to 90% by weight). By preparing the coating material to such a high solid content, a stable pattern can be formed by pressing. Moreover, thinning of the coating film can be suppressed, and three-dimensional design properties can be sufficiently expressed. When the solid content of the coating material is too low, it is difficult to form a concave portion by pressing, and it is difficult to obtain a clear concavo-convex feeling.

The viscosity of the coating material is usually 50 to 1500 Pa · s, preferably 100 to 1000 Pa · s, more preferably 200 to 800 Pa · s. Further, the thixotropy index (TI value) of the coating material is usually 3.0 or more, preferably 4.0 to 8.0, more preferably 5.0 to 7.0. By adjusting the viscosity and TI value of the coating material within such ranges, workability during pressing, finishing of the pressing portion, and the like can be improved. When the viscosity of the coating material is too low, the shape of the coating film changed by pressing is not maintained, and the boundary between the concave portion and the convex portion becomes unclear. If the viscosity of the coating material is too high, the pressing operation cannot be performed efficiently. When the TI value of the coating material is too low, the coating material is easily caught by the pressing tool. Moreover, the coating film shape changed by pressing is not maintained, and the boundary between the concave portion and the convex portion becomes unclear.
In addition, the viscosity said here is a viscosity (guide value of the 2nd rotation) in 2 rpm measured with the BH type | mold viscosity meter at the temperature of 23 degreeC, and TI value is a value calculated | required by the following formula.
<Formula> TI value = η1 / η2
(In the formula, η1 represents the apparent viscosity at 2 rpm (Pa · s: guide value for the second rotation), and η2 represents the apparent viscosity at 20 rpm (Pa · s: guide value for the fourth rotation). ℃.)

In the present invention, the coating material as described above is applied to the substrate so that the average film thickness is 0.5 to 15 mm (preferably 1 to 12 mm). When the average film thickness of the coating material is too small, the unevenness due to pressing becomes poor. If the average film thickness of the coating material is too large, it may be disadvantageous in terms of drying properties and cost, and the load on the substrate may be increased.
In addition, the average film thickness of the coating film in this invention is an average value of the film thickness in the undried coating film immediately after coating.

  As a coating method, a known method can be adopted. Specifically, methods such as spray coating, roller coating, brush coating, and iron coating can be employed. At this time, the coating thickness may be changed to some extent. Further, after painting, the coated surface may be treated with a design roller, a brush, a comb, a spatula or the like.

  Next, after the coating material is applied, the coating material is pressed using a pressing tool having a width of 0.5 times or more of the average film thickness of the coating material while the coating material is undried. In the present invention, by using a pressing tool having such a specific shape, a concave portion corresponding to the shape of the pressing tool is formed at the time of pressing, and the coating material around the pressing portion is appropriately raised, and the shape of the coating material Is retained after pressing. By such an action, the boundary between the concave portion (pressing portion) and the convex portion (non-pressing portion) becomes clear, and a sharp uneven pattern can be obtained. In addition, the width | variety of the pressing tool in this invention is a dimension of the short direction of a pressing tool bottom face.

  As the pressing tool, one having a width of 0.5 times or more with respect to the average film thickness of the coating material can be used, but a pressing tool whose width is 1.0 times or more, and further 1.5 times or more is used. As a result, the sharpness of the uneven pattern can be further enhanced. Although the upper limit of the width | variety of a pressing tool is not specifically limited, Usually, it should just be in the range of 50 times or less with respect to the average film thickness of a coating material.

An example of the pressing tool is shown in FIG.
In the pressing tool of FIG. 1, a handle B is attached to the main body A. In the pressing tool of FIG. 1, the handle B is attached for the purpose of efficiently performing the pressing operation. However, the handle B can be omitted if the pressing can be performed only by the main body A.
The width 10 of the main body A is set larger than the average film thickness of the coating material. The bottom surface of the main body A has a shape as shown in FIG. The material of the main body A is not particularly limited, and examples thereof include plastic, wood, and metal. The portion where the main body A and the coating material are in contact with each other may be treated with a release agent or the like as necessary.
The height 11 is desirably larger than the average film thickness of the coating material. If it is such an aspect, the rise around a press part will become moderate.

  Another example of the pressing tool is shown in FIG. The pressing tool in FIG. 3 has a trapezoidal bottom surface (FIG. 4), and its width gradually changes. In the case of such a pressing tool, it is sufficient that the width is larger than the average film thickness of the coating material at least in the maximum width portion (width 12), but even in the minimum width portion (width 13). If is larger than the average film thickness of the coating material, a more desirable effect can be obtained. Further, when the width of the pressing tool is changed, a change also occurs in the swell of the coating material around the pressing portion, so that the boundary portion of the concavo-convex pattern becomes clearer.

  In addition, in the present invention, pressing tools having various shapes as shown in FIG. 5 can be used.

  The timing with which the coating film is pressed by the pressing tool may be within a time in which the coating film is in an undried state and can be deformed by pressing. Even if the outermost surface of the coating film is in a dry state (touch-drying state), pressing is possible if the inside of the coating film is in an undried state (state before curing and drying). The pressing can be performed after the main body A is immersed in water, a solvent, or the like.

  After the pressing, the coating film may be dried as it is. Drying may usually be performed at room temperature (about 5 to 40 ° C.). When drying at room temperature, a cured coating film can usually be formed by providing a drying time of 24 hours or longer after coating. In addition, drying of a coating material can also be performed under high temperature as needed.

  In the present invention, a novel concavo-convex pattern surface that has not existed in the past can be obtained by appropriately setting the shape of the pressing tool or by variously changing the pressing pattern.

  In the present invention, even if it is a vertical surface, dripping or the like does not occur, and a clear uneven pattern can be obtained. Therefore, the method of the present invention can be preferably applied particularly to wall surfaces.

In the present invention, after the coating material is dried, a clear paint, a water repellent or the like can be applied as necessary. Among these, examples of the clear paint include acrylic resin-based paints, urethane resin-based paints, epoxy resin-based paints, acrylic silicon resin-based paints, and fluororesin-based paints. Such a clear paint can also adjust the degree of gloss by blending a matting agent or the like. Moreover, as long as the effect of this invention is not inhibited, it can also color. As the water repellent, those having an alkoxysilane compound, a silicone resin or the like as a main component can be used.
As a method of applying such a clear paint or water repellent, a known method can be employed, and for example, spray coating, roller coating, brush coating, or the like can be employed.

Examples are given below to clarify the features of the present invention.
In the production of the coating material, the following raw materials were used.
・ Resin: Acrylic resin emulsion, solid content 50% by weight, minimum film forming temperature 20 ° C.)
Coloring pigment: Titanium oxide dispersion (solid content 70% by weight, particle size 0.3 μm)
・ External pigment: heavy calcium carbonate (particle size 5-10 μm)
-Aggregate 1: Cold water stone (particle diameter 0.1-0.3mm)
Aggregate 2: colored silica sand (brown / red / light yellow mixture, particle size 0.1 to 0.2 mm)
-Aggregate 3: Natural mica (particle diameter 0.8-1.2mm)
-Aggregate 4: Shell pieces (particle diameter 2-4mm)
-Film-forming aid 1: 2,2,4-trimethyl-1,3-pentanediol monoisobutyrate-Film-forming aid 2: Ethylene glycol monobutyl ether-Thickener 1: Cellulosic thickener (solid content 100% by weight)
-Thickener 2: Polyurethane thickener (solid content 50% by weight)
-Antifoaming agent: Silicone-based antifoaming agent (solid content 50% by weight)

Example 1
40 parts by weight of color pigment, 150 parts by weight of extender pigment, 280 parts by weight of aggregate 1, 14 parts by weight of film-forming aid 1, 60 parts by weight of water, and thickener 1 with respect to 200 parts by weight of resin 5 parts by weight and 3 parts by weight of an antifoaming agent were uniformly mixed by a conventional method to prepare a coating material 1. In this coating material 1, the proportion of powder particles in the coating material was 61% by weight, the solid content was 75% by weight, the viscosity was 500 Pa · s, and the TI value was 5.5.

  The coating material 1 was troweled to a slate plate (90 × 90 cm) that had been previously sealed with a sealer. At this time, the average film thickness of the undried coating film (calculating the average value at 10 locations) was 5 mm. Next, the surface of the undried coating film was continuously pressed using a pressing tool (width 10 to 30 mm, height 30 mm, length 200 mm) shown in FIG. 3 to form the pattern shown in FIG. 6. . After finishing the drying for 24 hours, the finish was confirmed. As a result, the boundary between the pressing part and the non-pressing part was clear and a sharp uneven pattern could be obtained. The painting work and drying were all performed at a temperature of 23 ° C. and a relative humidity of 50%.

(Example 2)
400 parts by weight of aggregate 2, 15 parts by weight of aggregate 3, 20 parts by weight of aggregate 4, 10 parts by weight of film-forming aid 1, 30 parts by weight of water, and 200 parts by weight of thickener 1 part by weight of 1 and 3 parts by weight of an antifoaming agent were uniformly mixed by a conventional method to produce a coating material 2. In this coating material 2, the powder / particle ratio in the coating material was 64 wt%, the solid content was 79 wt%, the viscosity was 350 Pa · s, and the TI value was 5.3.
A pattern surface was formed in the same manner as in Example 1 except that the coating material 2 was used instead of the coating material 1. The average film thickness of the undried coating film was 6 mm. In Example 2, the boundary between the pressing portion and the non-pressing portion was clear, and a sharp uneven pattern could be obtained.

(Comparative Example 1)
40 parts by weight of color pigment, 150 parts by weight of extender pigment, 280 parts by weight of aggregate 1, 4 parts by weight of film-forming aid 1, 10 parts by weight of film-forming aid 2 with respect to 200 parts by weight of resin, water 60 parts by weight, thickener 2 6 parts by weight, and antifoaming agent 3 parts by weight were uniformly mixed by a conventional method to prepare coating material 3. In this coating material 3, the proportion of powder particles in the coating material was 61% by weight, the solid content was 75% by weight, the viscosity was 100 Pa · s, and the TI value was 2.8.
A pattern surface was formed in the same manner as in Example 1 except that the coating material 3 was used instead of the coating material 1. The average film thickness of the undried coating film was 5 mm. In Comparative Example 1, the boundary between the pressing part and the non-pressing part has been lost.

(Comparative Example 2)
40 parts by weight of color pigment, 150 parts by weight of extender pigment, 280 parts by weight of aggregate 1, 14 parts by weight of film-forming aid 2, 60 parts by weight of water, and thickener 1 with respect to 200 parts by weight of resin A coating material 4 was produced by uniformly mixing 1 part by weight and 3 parts by weight of an antifoaming agent by a conventional method. In this coating material 4, the proportion of powder particles in the coating material was 61% by weight, the solid content was 75% by weight, the viscosity was 45 Pa · s, and the TI value was 3.6.
A pattern surface was formed in the same manner as in Example 1 except that the coating material 4 was used instead of the coating material 1. The average film thickness of the undried coating film was 5 mm. In Comparative Example 2, the boundary between the pressing portion and the non-pressing portion has been lost.

(Comparative Example 3)
A pattern surface was formed in the same manner as in Example 1 except that a pressing tool having a rectangular parallelepiped shape with a width of 2 mm, a height of 30 mm, and a length of 200 mm was used. The average film thickness of the undried coating film was 5 mm. In Comparative Example 3, a clear uneven pattern as in Example 1 was not obtained.

It is a figure which shows an example of a pressing tool. It is a figure which shows the bottom face of a pressing tool (FIG. 1). It is a figure which shows another example of a pressing tool. It is a figure which shows the bottom face of a pressing tool (FIG. 3). It is a figure (bottom view) which shows another example of a pressing tool. It is a figure which shows an example of the pattern surface by this invention.

Explanation of symbols

A: Body B: Handle 10: Width 11: Height 12: Width 13: Width 14: Height

Claims (1)

An aqueous resin and granular material are essential components, and the granular material is contained in the coating material in an amount of 30 to 80% by weight, the solid content of the coating material is 50 to 95% by weight, the viscosity is 50 to 1500 Pa · s, and the thixotropic index. Is applied to the base material so that the average film thickness is 0.5 to 15 mm,
A pattern forming method characterized in that, while the coating material is undried, the coating film is pressed using a pressing tool having a width of 0.5 times or more of the average film thickness of the coating material to form an uneven pattern.

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