JP2017185487A - Film formation method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a film coating method capable of efficiently providing an uneven pattern having a random beautiful appearance.SOLUTION: A film formation method comprises the steps, sequentially performed, for: (1) coating a surface of a base material with a covering material containing an aqueous resin and powder particles and having a containing ratio of the powder particles of 30-90 wt.%, a heated remainder of 50-95 wt.%, and a flow value of 100-180 mm; (2) pressing a flat plate onto the coated surface of the covering material before the coated surface is dried, and pulling up the flat plate from the coated surface to provide a convexoconcave condition on the coated surface; and (3) beating the coated surface using a wet tool to process the convexoconcave condition on the coated surface.SELECTED DRAWING: None

Description

  The present invention relates to a novel film forming method.

  Conventionally, a concavo-convex pattern such as a natural stone has been formed on the surface of an interior / exterior wall of a building or a civil engineering structure for the purpose of improving aesthetics. As means for obtaining such a concavo-convex pattern, methods using various coating materials are known.

  For example, Japanese Patent Application Laid-Open No. 5-68937 (Patent Document 1) describes a method of providing a concavo-convex pattern using a net and a spraying material. Specifically, according to the method of the publication, after a grid-like net is installed on the wall surface using an adhesive, a spraying material is applied to make a void in the net into a recess.

JP-A-5-68937

  However, in the method described in the above publication, the uneven pattern is formed according to the lattice shape of the net, so the interval between the uneven parts becomes regular.

  Moreover, in the method described in the above publication, the uneven pattern is formed by using three kinds of materials, that is, an adhesive, a net, and a spraying material. For this reason, the work for forming the concavo-convex pattern becomes complicated, and there is a risk of prolonging the construction period.

  This invention is made | formed in view of such a point, and it aims at obtaining the uneven | corrugated pattern which has random aesthetics efficiently.

  In order to solve such a problem, the present inventors, as a result of intensive studies, sequentially perform a step of applying a specific coating material to a base material and a step of imparting irregularities to the coating surface by a specific method. The present invention has been completed.

That is, the present invention has the following characteristics.
1. A method of forming a film having a concavo-convex pattern, on a substrate,
(1) A coating material containing an aqueous resin and powder, the content of the powder being 30 to 90% by weight, the heating residue being 50 to 95% by weight, and the flow value being 100 to 180 mm is applied. Process,
(2) While the coating surface of the coating material is undried, pressing the flat plate against the coating surface and pulling up the flat plate from the coating surface, thereby imparting irregularities to the coating surface,
The film formation method characterized by performing sequentially.
2. Following the step (1) and the step (2),
(3) a step of treating the unevenness of the coated surface,
Are performed in order. The film formation method of description.
3. The step (3) is a step of hitting the coated surface with a wet instrument while the coated surface is undried. The film formation method of description.

  According to the present invention, it is possible to efficiently obtain a concavo-convex pattern having random aesthetics. In the present invention, a deep and large uneven pattern can be formed.

FIG. 1 is a bottom view showing an example of a flat plate. FIG. 2 is a cross-sectional view showing an example of a device having a flat plate.

1: Flat plate 10: Tip portion 11: Tip vertex 12: Bottom portion 13: Bottom both ends 14: Center portion 15: Lower surface 16: Upper surface 2: Handle 3: Support material L: Flat plate length W: Flat plate width

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

  The present invention can be applied mainly to the inner and outer wall surfaces, ceilings, floors, etc. of buildings, or the surface of civil engineering structures. As a base material constituting such a part, for example, concrete, mortar, siding board, extrusion board, gypsum board, pearlite board, plywood board, plastic board, metal board, wood board, glass, brick, ceramic tile, etc. Various base materials are mentioned. These base materials may have been subjected to some surface treatment (filler treatment, surfacer treatment, sealer treatment, etc.), or may be pre-colored with a colored paint or the like. It may be attached.

  In this invention, with respect to the said base material, as process (1), an aqueous resin and a granular material are included, the content rate of the said granular material is 30 to 90 weight%, a heating residue is 50 to 95 weight%, flow A coating material having a value of 100 to 180 mm is applied. A covering material having such physical property values is suitable for forming an uneven pattern in the present invention.

  The aqueous resin acts as a binder. Examples of the aqueous resin include water-dispersible resins and / or water-soluble resins. Examples of these resins include acrylic resins, urethane resins, epoxy resins, vinyl chloride resins, vinyl acetate resins, acrylic silicon resins, fluororesins, polyvinyl alcohol, cellulose derivatives, and composites thereof. Such a resin component may have a property of causing a crosslinking reaction after film formation.

  Examples of powder particles include extender pigments, colored pigments, and aggregates. These can be used alone or in combination of two or more.

  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, hollow beads, etc. Is mentioned. The average particle size of these extender pigments is preferably less than 50 μm, more preferably 0.5 μm to 45 μm, and still more preferably 1 μm to 40 μm. The average particle diameter of the extender pigment is a value measured by a laser diffraction particle size distribution measuring device.

  Examples of color pigments include titanium oxide, zinc oxide, carbon black, ferric oxide (bengara), 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. The average particle diameter of these colored pigments is preferably 10 μm or less, more preferably 0.01 μm or more and 1 μm or less, and further preferably 0.03 μm or more and 0.8 μm or less. The average particle diameter of the color pigment is a value measured by a laser diffraction particle size distribution measuring device.

  Examples of the aggregate include garnet, quartz sand, gravel, glass beads, resin beads, metal particles, or crushed products such as rocks, glass, ceramics, shells, sintered bodies, plastics, and rubbers. These may be subjected to a coloring treatment. The average particle diameter of these aggregates is preferably 0.05 mm or more and 5 mm or less, more preferably 0.06 mm or more and 2 mm or less. In addition, the average particle diameter of aggregate is a value obtained by performing sieving using a metal net sieve specified in JIS Z8801-1: 2000 and calculating the average value of the weight distribution.

  The aspect containing the above-mentioned extender pigment, colored pigment, and aggregate as the powder is preferable in the present invention. The weight ratio (external pigment: colored pigment: aggregate) of these powder particles is preferably 100: (1-100) :( 10-1000), more preferably 100: (5-80) :( 50- 800). If the ratio of each granular material is in such a range, the uneven | corrugated pattern which has depth and smoothness will be easy to form, and it is more suitable. Moreover, it becomes easy to obtain the coating | covering material which has the said flow value.

  The content rate of the granular material in a coating | covering material is 30 to 90 weight% normally, Preferably it is 40 to 85 weight%. When the content rate of a granular material does not satisfy the said range, the uneven | corrugated pattern formation by flat plate raising becomes difficult. Moreover, when the content rate of a granular material is too lower than the said value, thickness increase will become difficult and it will become difficult to obtain the uneven | corrugated pattern which has depth. When the content rate of a granular material is too higher than the said value, there exists a possibility that a malfunction may be produced in film physical properties, such as adhesiveness.

  In addition to the above components, the covering material is, for example, a diluent, a film-forming aid, a curing agent, a plasticizer, an antiseptic, an antifungal agent, an anti-algae agent, an antibacterial agent, a thickener, an antifoaming agent, a leveling agent, Includes surfactants, dispersants, anti-settling agents, anti-sagging agents, wetting agents, catalysts, curing accelerators, antifoaming agents, matting agents, anti-freezing agents, UV absorbers, antioxidants, light stabilizers, etc. It may be a thing.

  The heating residue of the coating material is usually 50 to 95% by weight, preferably 60 to 90% by weight. When the heating residue of the coating material does not satisfy the above range, it becomes difficult to form the uneven pattern by pulling up the flat plate. Moreover, when the heating residue of a coating | covering material is too lower than the said value, thickness increase will become difficult and it will become difficult to obtain the uneven | corrugated pattern which has depth. If the heating residue of the coating material is too higher than the above value, the workability during application may be hindered. In addition, the heating residue of a coating | covering material is the value measured by the method of JISK5601-1-2, heating temperature is 105 degreeC and heating time is 60 minutes.

  The flow value of the coating material is usually 100 to 180 mm, preferably 110 to 160 mm, and preferably 115 to 155 mm. When the flow value of the covering material does not satisfy the above range, it is difficult to form the uneven pattern by pulling up the flat plate. Moreover, when the flow value of a coating | covering material is too lower than the said value, there exists a possibility of affecting the workability | operativity at the time of application | coating. When the flow value of the coating material is too higher than the above value, it is difficult to obtain a concave-convex pattern having a depth. In addition, the flow value of a coating | covering material is a value measured by JISR5201 "11. Flow test", and measurement temperature is 23 degreeC. Such a flow value can be adjusted by, for example, the structure of the powder and the heating residue of the coating material.

In the step (1), the coating material is applied to the substrate. The method for applying the coating material is not particularly limited, and for example, methods such as spray coating, roller coating, and iron coating can be employed. The coating amount of the coating material is preferably 0.2 to 8 kg / m ² (more preferably 0.5 to 6 kg / m ² ).

  In the step (2), while the coating surface of the coating material is undried, a flat plate is pressed against the coating surface, and the flat surface is pulled up from the coating surface, thereby providing irregularities on the coating surface. In the present invention, since the covering material having the above-described characteristics is used, when the flat plate is pressed against the coating surface and pulled up, the covering material is pulled together with the flat plate and lifted. By repeating this operation while changing the place as appropriate, a random, deep and large uneven pattern is formed. Examples of the concavo-convex pattern include a ripple shape, a mountain shape, a hill shape, and a hump shape. The depth of the concavo-convex pattern is preferably 1 to 10 mm, more preferably 2 to 8 mm. In the present invention, such a concavo-convex pattern can be obtained more stably by using a flat plate having flexibility. In addition, the undried in this invention refers to the state before hardening drying.

  Examples of the material for the flat plate include metal, resin, and wood. Among these, metal is preferable. Examples of the metal plate include an iron plate, a steel plate, an aluminum plate, and a stainless plate. The thickness of a flat plate becomes like this. Preferably it is 0.1-1 mm, More preferably, it is 0.2-0.8 mm.

  As a tool provided with such a flat plate, a scissors having a pointed tip portion and a flat plate having a flexible tip portion is suitable. An example is shown in FIGS. In the present invention, by using such a wrinkle, a concavo-convex pattern film can be formed by a relatively simple operation. Such an effect is that a pressure is easily applied to the tip portion 10 of the flat plate 1 with a relatively small force during use, whereby the tip portion 10 of the flat plate 1 bends and the tip portion 10 is applied over a relatively large area. It is thought that the fact that it is easy to touch the surface contributes.

  FIG. 1 shows an example of a flat plate 1. The lower surface 15 of the flat plate 1 is a portion in contact with the coating surface (coating surface before drying) of the coating material.

  FIG. 1 shows the flat plate 1 viewed from the lower surface 15 side. The tip portion 10 of the flat plate 1 shown in FIG. 1 has a pointed shape. Examples of the shape of the distal end portion 10 include an inverted V shape, an inverted U shape, and the like, and an inverted V shape is preferable in the present invention. The angle (inner angle) of the tip end vertex 11 is preferably 60 to 120 °, more preferably 70 to 110 °.

  The bottom part 12 of the flat plate 1 should just have the shape similar to bottom parts, such as a square or a triangle, for example. The angle (inner angle) of the bottom end 13 may be a substantially right angle, preferably 70 to 100 °, more preferably 80 to 95 °. The length L (dimension from the lower end to the upper end) of the plate 1 is preferably 100 to 400 mm, more preferably 150 to 350 mm. The width W of the plate 1 is preferably 30 to 150 mm, more preferably 40 to 120 mm.

  As such a bag, as shown in FIG. 2, a plate provided with a plate 1 and a handle 2 can be used. As shown in FIG. 2, the handle 2 should just be installed in the upper surface 16 side of the flat plate 1 via the support material 3 grade | etc.,. The position of the handle 2 may be in the vicinity of the central portion 14 of the flat plate 1 or between the central portion 14 and the bottom portion 12.

  In this invention, it is desirable to perform the process of processing the unevenness | corrugation of the said coating surface as a process (3) following the said process (1) and a process (2). By such a process (3), the shape of the concavo-convex pattern formed in the process (2) can be adjusted. In particular, rounding or smoothness can be imparted to the concavo-convex pattern by smoothing the surface layer of the coating surface. Examples of such a smoothing treatment include polishing after drying the coating surface, pressing before drying the coating surface, and the like. In the step (3), it is desirable to maintain the basic shape of the concavo-convex pattern, and the depth of the concavo-convex pattern after processing is preferably 1 to 10 mm, more preferably 2 to 8 mm.

  Among these, the pressing before drying the coated surface includes, for example, a method of performing a smoothing process using an instrument such as a roller, a brush, or a sponge while the coated surface is not dried. Such a method is advantageous in that the work period is shortened because the coating surface is undried, and, unlike polishing, dust is not generated.

  In the present invention, as the step (3), it is desirable to perform a step of hitting the coated surface using a wet instrument while the coated surface is not dried. In such a step (3), the coated surface is hit using a wet instrument (hereinafter also referred to as “tapping tool”) while the coated surface is not dried. In the present invention, by this step (3), smoothness can be imparted to the surface while maintaining the depth of the concavo-convex pattern formed in the step (2). Such an effect is that the basic shape of the concavo-convex pattern is difficult to be damaged by the characteristics of the coating material, and an appropriate pressure on the coating surface by the hitting tool, and the vicinity of the coating surface surface layer by using the wet hitting tool It is considered that the surface layer of the coating surface tends to become smooth due to a decrease in viscosity or the like, and so on. Such effects are difficult to obtain with tools such as brushes.

  As such a hitting tool, one having flexibility is preferable, and for example, a sponge material or a fiber material is suitable. Specific examples of the hitting tool include a dandelion, a sponge, and a felt. The surface shape of the hitting tool is not particularly limited, and may be any of a square, a triangle, a circle, an indeterminate shape, and the like. The hitting tool can be provided with a handle or the like as required.

  Water and / or solvent can be used to wet the hitting tool. In the present invention, it is desirable to wet with at least water.

  When the coating surface is hit with a hitting tool, the uneven pattern can be adjusted by appropriately changing the degree of wetting, the pressure and the number of times of hitting, and the like. It is also possible to strike while randomly changing the direction of the hitting tool. In such a step (3), it is desirable to hit the coating surface with a hitting tool for the entire coating surface (over the entire coating surface).

  After such step (3), the covering material can be dried. Drying is preferably performed at room temperature (0 to 40 ° C.).

  In this invention, a finishing material can be apply | coated after the said process. As such a finishing material, for example, a transparent finishing material, a colored finishing material, or the like can be used. Among these, when a colored finishing material is used, it becomes possible to finish in a desired color tone. Examples of the colored finish include synthetic resin emulsion paint, glossy synthetic resin emulsion paint, non-aqueous dispersion type resin enamel, and multicolored paint.

  A publicly known instrument can be used for applying the finishing material. As such an instrument, for example, a spray, a roller, a brush, a iron or the like can be used. What is necessary is just to set the coating amount of a finishing material suitably according to the kind of finishing material to be used, the kind of apparatus, etc. The finishing material is preferably dried at room temperature (0 to 40 ° C.).

  Examples are given below to clarify the features of the present invention.

Example 1
150 parts by weight of extender pigment (heavy calcium carbonate, average particle size 10 μm) and 200 parts by weight of pigment (titanium oxide) with respect to 200 parts by weight of aqueous resin (acrylic resin emulsion, heating residue 50% by weight, minimum film-forming temperature 20 ° C.) , 30 parts by weight of the average particle diameter 0.3 μm), 250 parts by weight of the aggregate 1 (cold stone, average particle diameter 0.2 mm), 350 parts by weight of the aggregate 2 (silica sand, average particle diameter 0.5 mm), 14 parts by weight of a film-forming aid, 90 parts by weight of water, 4 parts by weight of a thickener, and 3 parts by weight of an antifoaming agent (50% by weight of heating residue) Manufactured. In this covering material 1, the content rate of the granular material is 71% by weight, the weight ratio of each granular material (external pigment: colored pigment: aggregate) is 100: 20: 400, the heating residue is 81% by weight, the flow The value was 135 mm.

On the slate plate on which the undercoat has been applied in advance, the coating material 1 is smoothly applied at 4 kg / m ² , and the coating surface is undried while the coating surface is not dried. Raised. This operation was repeated while changing the place to form a random uneven pattern. In addition, as a cage | basket, it has what has the form shown in FIGS. 1-2 (a flat plate: The product made from stainless steel, the thickness of a flat plate: 0.3 mm, the angle of a vertex of a front-end | tip part: 90 degrees, the length of a flat plate: 210 mm, the width of a flat plate: 60 mm) was used. Next, while the coated surface was undried, the coated surface was struck entirely with a sponge moistened with water and then dried at 23 ° C. for 24 hours to form a coating film. From the above, a film having a knurled uneven pattern having a depth of about 3 to 4 mm and smoothness on the surface of the film was obtained.

(Example 2)
200 parts by weight of aqueous resin (same as above), 240 parts by weight of extender pigment (same as above), 35 parts by weight of colored pigment (same as above), 300 parts by weight of aggregate 1 (same as above) and 350 parts of aggregate 2 (same as above) Part by weight, 14 parts by weight of a film-forming aid, 86 parts by weight of water, 4 parts by weight of a thickener, and 3 parts by weight of an antifoaming agent were uniformly mixed by a conventional method to produce a coating material 2. In this covering material 2, the content rate of the granular material is 75% by weight, the weight ratio of each granular material (external pigment: colored pigment: aggregate) is 100: 15: 271, the heating residue is 84% by weight, and the flow The value was 115 mm.

  A coating film was formed in the same manner as in Example 1 except that the coating material 2 was used instead of the coating material 1. From the above, a hump-like uneven pattern having a depth of about 3 to 5 mm and smoothness on the surface of the coating was obtained.

(Example 3)
130 parts by weight of extender pigment (same as above), 20 parts by weight of colored pigment (same as above), 180 parts by weight of aggregate 1 (same as above), and 280 of aggregate 2 (same as above) with respect to 200 parts by weight of aqueous resin (same as above) Part by weight, 14 parts by weight of a film-forming aid, 94 parts by weight of water, 4 parts by weight of a thickener, and 3 parts by weight of an antifoaming agent were uniformly mixed by a conventional method to produce a coating material 3. In this coating material 3, the content of the granular material is 66% by weight, the weight ratio of each granular material (external pigment: colored pigment: aggregate) is 100: 15: 354, the heating residue is 77% by weight, the flow The value was 152 mm.

A coating film was formed in the same manner as in Example 1 except that the coating material 3 was used instead of the coating material 1. From the above, a hump-like uneven pattern having a depth of about 2 to 3 mm and smoothness on the surface of the coating was obtained.

Claims (3)

A method of forming a film having a concavo-convex pattern, on a substrate,
(1) A coating material containing an aqueous resin and powder, the content of the powder being 30 to 90% by weight, the heating residue being 50 to 95% by weight, and the flow value being 100 to 180 mm is applied. Process,
(2) While the coating surface of the coating material is undried, pressing the flat plate against the coating surface and pulling up the flat plate from the coating surface, thereby imparting irregularities to the coating surface,
The film formation method characterized by performing sequentially. Following the step (1) and the step (2),
(3) a step of treating the unevenness of the coated surface,
The film forming method according to claim 1, wherein the steps are performed in order. 3. The film forming method according to claim 2, wherein the step (3) is a step of hitting the coated surface using a wet instrument while the coated surface is undried.

Images