JP2023180245A - Coating method - Google Patents

Abstract

To provide a coating method capable of efficiently and simply performing excellent pattern design finishing by roller coating.SOLUTION: A coating method applies a coating material by using a special porous roller having a plurality of depressions.SELECTED DRAWING: Figure 1

Description

The present invention relates to a novel coating method.

Examples of materials for forming a colorful coating film include coating materials having particles of two or more colors. According to such a coating material, it is possible to obtain a patterned finish in which grains (particles) of two or more colors are interspersed, and in recent years, it has been suitably used on the walls of buildings and the like.

Recently, designs similar to those found in natural stone have become popular.

For coating with such a coating material, a spraying type device such as a spray gun is usually used (for example, Patent Documents 1 and 2). However, from the viewpoint of material loss, there has recently been a demand for switching to roller type instruments.

Japanese Patent Application Publication No. 2001-20487 Japanese Patent Application Publication No. 2004-99911

For example, the above-mentioned patent document also describes coating using a roller.
However, when a roller-type device is actually used, the coating material is not transferred well from the roller to the base, making it impossible to obtain the desired pattern.Additionally, the amount of coating material transferred is small in one application, and multiple applications are required. There are problems such as poor workability as it may require painting.

As a result of intensive studies to solve these problems, the inventors of the present invention found that by using a special roller, more coating material can be transferred to the base material in one application, which is an excellent solution. The inventors have discovered that it is possible to efficiently and easily finish a pattern design, and have completed the present invention.

That is, the present invention has the following features.
1. A coating method using a roller,
The roller is a porous roller,
The surface of the porous layer constituting the porous roller has a plurality of independent depressions, and the size of each depression is 2 mm or more and 30 mm or less,
The total area of the depressions on the surface of the porous roller is 10% or more and 80% of the entire roller surface,
The surface and inside of the porous layer constituting the porous roller have communicating pores, and the size of one hole is smaller than the size of one depression, and is 0.5 mm or more and 10 mm or less,
A coating method comprising applying a coating material containing particles having a size of 2 μm or more and less than 2 mm to a substrate using the roller.
2. 1. The depression has a depth of 1 mm or more and less than 25 mm. Coating method described in.
3. 1. The porous roller has a thickness of 1 mm or more and less than 25 mm. Coating method described in.

According to the coating method of the present invention, an excellent pattern design can be efficiently and easily finished by roller coating.

This is an example of a roller used in the present invention. FIG. 2 is an enlarged view of the surface of the porous layer in FIG. 1. FIG. FIG. 2 is an enlarged cross-sectional view (PP′ cross section) of a porous layer having communicating holes.

X: Hollow Y: Hole Y1: Open pore (surface of porous layer)
Y2: Communication hole a: Size of depression b: Distance between depressions 1: Core material 2: Reinforcement material 3: Handle shaft 4: Porous layer 5: Handle

EMBODIMENT OF THE INVENTION Hereinafter, the form for implementing this invention is demonstrated in detail.

The present invention relates to a coating method using a roller, and the roller is a porous roller, and the surface of a porous layer constituting the porous roller has a plurality of independent depressions, and one depression is a single depression. The size is 2 mm or more and 30 mm or less, the total area of the depressions on the surface of the porous roller is 10% or more and 80% of the entire roller surface, and the surface and inside of the porous layer constituting the porous roller is , has a communicating hole, the size of each hole is smaller than the size of one depression, and is 0.5 mm or more and 10 mm or less, and using the roller, a coating material containing particles with a size of 2 μm or more and less than 2 mm is applied to the substrate. By applying it to wood, it is possible to efficiently and easily create an excellent pattern finish.
The present invention uses a porous roller suitable for coating materials containing particles with a size of 2 μm or more and less than 2 mm.

<Porous roller>
The porous roller used in the present invention has a porous layer on the outer surface of a cylindrical core material, for example, as shown in FIG. It is hollow so that a handle can be attached to it, and a handle shaft can be attached to the cavity for use.

The cylindrical core material is not particularly limited, and for example, core materials made of plastic, wood, metal, etc. can be used. A reinforcing material made of plastic, rubber, glass, metal, fiber, etc. can also be used between the core material and the core material.

The porous roller of the present invention has a plurality of independent depressions on its surface (the surface of the porous layer constituting the porous roller). Note that "independent depressions" are depressions that exist on the surface of the porous layer in a state where adjacent depressions are separated from each other by the porous material of the porous layer.

The surface and inside of the porous layer constituting the porous roller of the present invention has a large number of "pores", and there is no membrane-like material separating the pores, and the pores are interconnected. (See Figure 3).

By using such a porous roller, particles can easily enter the recesses, and coating material components can also easily enter the holes, allowing more coating material to be included in the porous layer, allowing for a single application. With this method, more coating material can be transferred, and the process can be performed efficiently and easily.

The shape of one depression is not particularly limited, and may be, for example, circular, oval, triangular, square, hexagonal, polygonal, etc. when viewed from the surface of the porous roller.

The size of each depression, when viewed from the surface of the porous roller, is preferably 2 mm or more and 30 mm or less, more preferably 5 mm or more and 20 mm or less, still more preferably 6 mm or more and 18 mm or less, and most preferably 7 mm or more and 15 mm or less. Due to this size, particles with a size of 2 μm or more and less than 2 mm contained in the coating material can be easily contained in the depressions, and more coating material can be coated with one application. can be transferred to a substrate.
The size of the depression can be calculated by multiplying the maximum distance from the center of gravity of each shape by 2. For example, for a circle, calculate the diameter, for an oval, the major axis, and for an equilateral triangle, calculate the length of one side. If L, it can be calculated by L cos 30°×4/3, the length of the diagonal in the case of a regular quadrangle, the diameter of the circumscribed circle in the case of a regular hexagon, etc.

Note that the shape and size of the depressions refer to the shape and size on the surface of the porous roller.

The size of the plurality of depressions on the surface of such a porous layer is preferably 1.5 times or more (more preferably 2 times or more) larger than the size of the pores.

In addition, the total area of the depressions on the surface of the porous roller (the sum of the areas of the depressions) is 10% or more and 80% or less (preferably 13% or more and 70% or less) of the entire roller surface area (the area of the outer peripheral surface of the roller). , more preferably 16% or more and 60% or less, still more preferably 19% or more and 50% or less). When the total area of the depressions on the roller surface is within the above range, the coating material can be efficiently transferred to the base material.

The ratio (%) of the total area of the depressions on the surface of the porous roller can be determined by dividing the total area of the depressions by the surface area of the roller (width of the roller x circumference of the surface of the roller). For example, if the depression is circular in size and has a uniform size, it can be determined by (area of circle x number)/(surface area of roller) x 100. If the shape is random, a development diagram of the roller surface can be created and the total area of the depressions can be determined from there.

The depth of the depression is preferably 1 mm or more and less than 25 mm, more preferably 3 mm or more and 20 mm or less, still more preferably 5 mm or more and 18 mm or less, and most preferably 7 mm or more and 15 mm or less. The shape in the depth direction is not particularly limited, but for example, if the surface shape is circular, it may have the same shape in the depth direction such as a cylinder, or it may have a shape that is the same in the depth direction such as a cone or truncated cone. It is preferable that the size decreases in the direction. Note that the depth of the depression is the distance from the surface of the porous roller to the deepest part that is farthest from the surface.

The porous roller used in the present invention has a plurality of such depressions. The arrangement of the depressions may be random or regular. In the present invention, it is preferable that the depressions are arranged regularly, for example, when viewed from the surface of the porous roller, large circles and small circles are arranged alternately, or circles and triangles are arranged alternately. , a case where circles A, B, and C are arranged regularly, although the interval between circles A and B and the interval between circles B and C are different, is also an example of a regular arrangement.

In the present invention, it is particularly preferable that depressions of uniform size and/or shape are regularly arranged. It is preferable that such depressions are arranged at equal intervals.

As shown in FIG. 2, the porous roller used in the present invention has a distance (b) between adjacent depressions that is 1.05 times or more and 3.0 times or less relative to the size (a) of the depressions (b/a). (more preferably 1.1 times or more and 2.8 times or less, more preferably 1.2 times or more and 2.6 times or less). By regularly arranging them at such intervals, the design is not biased by the depressions, and it is easy to easily obtain a better pattern design. Note that the distance (b) between adjacent depressions is the distance between the centers of gravity of each depression shape.

The method for manufacturing a porous layer having a plurality of depressions is not particularly limited, but may include heating a part of a porous layer without depressions to melt it into a predetermined size and shape. It can be manufactured by cutting it out with a cutter, drill, etc., or molding it with a mold. Furthermore, the depressions may be made in the porous layer before the porous layer is attached to the cylindrical core material, or the depressions may be made in the porous layer after the porous layer is attached to the cylindrical core material. A porous roller having a plurality of such depressions can be used by being attached to a handle shaft.

The size of the pores in the porous layer is smaller than the size of one depression, 0.5 mm or more and 10 mm or less, more preferably 0.7 mm or more and 8 mm or less, still more preferably 1 mm or more and 6 mm or less, and most preferably 1. It is 2 mm or more and 5 mm or less.
In particular, the size of the pores is preferably larger than the size of the particles contained in the coating material, which will be described later. Particles can also be contained within the pores, and more coating material can be coated in one application. It is possible to transfer it to materials.
Note that the size of the hole may be calculated by multiplying the maximum distance from the center of gravity of each hole by 2. Further, the size of the pores can be determined, for example, from the open pores on the surface or cut surface. Further, the hole size is an average value calculated from 10 locations.

In the present invention, by setting the size of the depression and the size of the pore in the porous layer within the above range, more coating material can be contained inside the depression and the inside of the pore. It is possible to transfer more coating material to the substrate by applying . Furthermore, the coating material can be applied over a wide range of viscosity.

The material of the porous layer is not particularly limited, but examples include resins such as acrylic resin, urethane resin, ester resin, and ethylene resin, which are made porous into a sponge shape.

In contrast to the porous roller used in the present invention, fibrous rollers made of wool, synthetic fibers, etc. have uneven particles and are more likely to have uneven finish. Further, even if the roller has a porous layer, if it does not have depressions, sufficient transfer will not be possible, particles will be uneven, and uneven finish will likely occur.

The thickness of the porous roller (porous layer) is preferably 1 mm or more and less than 25 mm, more preferably 3 mm or more and 20 mm or less, still more preferably 5 mm or more and 18 mm or less, and most preferably 7 mm or more and 15 mm or less. With such a thickness, a large amount of coating material can be contained inside the hollows and holes of the porous roller, and efficient transfer is possible, resulting in excellent workability. Note that the thickness of the porous roller is a value obtained by measuring the thickness of the porous layer at a portion without depressions in the cross section of the porous layer.

The width (length) of the porous roller is not particularly limited, but is preferably about 80 mm or more and 250 mm or less. Further, the diameter (cylinder diameter) of the porous roller (including the porous layer) is preferably about 15 mm or more and 100 mm or less.

<Coating material>
The coating material used in the present invention is characterized by containing particles with a size of 2 μm or more and less than 2 mm (preferably 5 μm or more and 1 mm or less), and such particles are large enough to be visually recognized as granules on the surface of the base material. It is a material that creates a unique design. Note that the particle size is the maximum diameter when the particle is stably placed on a horizontal surface and observed from above. The maximum diameter here can be calculated by multiplying the maximum distance from the center of gravity of the shape by 2. The particle size can be measured using an optical microscope or the like.

The particles with a size of 2 μm or more and less than 2 mm used in the present invention are not particularly limited, but may be in a gel form, solid form, etc. in the coating material, but when coated on a base material, particles with a size of 2 μm or more and less than 2 mm It is a component that forms and obtains unique design patterns. The coating material can contain two or more different colored particles. The above-mentioned coating material can also contain particles with a size of 2 mm or more, but the particles with a size of 2 mm or more are preferably 10% by weight or less, more preferably 0% by weight, based on the total particles contained in the coating material. % or more and 5% by weight or less. Further, particles with a size of less than 2 μm may be included, but the particles with a size of less than 2 μm are preferably 10% by weight or less, more preferably 0% by weight or more and 5% by weight of all particles contained in the coating material. The following is sufficient.

When the particles are in gel form in the coating material, the particles preferably contain a colorant and a resin as components.

Examples of colorants include titanium oxide, zinc white, yellow iron oxide, orca, titanium yellow, carbon black, graphite, chrome green, cobalt green, ultramarine blue, deep blue, cobalt blue, cobalt violet, molybdate orange, red iron oxide, and permanent. Examples include colored pigments such as red, brilliant carmine, lake red, anthraquinone red, perylene red, fast yellow, permanent yellow, isosindrione yellow, quinophthalone yellow, phthalocyanine green, phthalocyanine blue, and quinacridone violet.

Examples of the resin include acrylic resin, acrylic silicone resin, silicone resin, epoxy resin, urethane resin, fluororesin, ethylene resin, vinyl acetate resin, polyester resin, alkyd resin, and vinyl chloride resin.

When the particles are solid in the coating material, the components of the particles include, for example, heavy calcium carbonate, agarite, light calcium carbonate, white carbon, talc, mica, kaolin, clay, china clay, china clay, diatomaceous earth. , barite powder, barium sulfate, precipitated barium sulfate, silica sand, silica powder, quartz powder, resin beads, crushed resin, glass beads, crushed glass, crushed ceramics, crushed ceramics, as well as marble, granite, serpentine. , granite, fluorite, agarite, feldspar, silica, silica sand, and crushed products thereof, among which one type or a combination of two or more types can be used. Moreover, the surface of the powder or granular material may be colored and coated. Furthermore, solid resin particles obtained by solidifying the above-mentioned gel-like particle components in advance can also be used.

The coating material preferably contains particles with a size of 2 μm or more and less than 2 mm and a binder. The binding material is a component that fixes particles, such as acrylic resin, acrylic silicone resin, silicone resin, epoxy resin, urethane resin, fluororesin, ethylene resin, vinyl acetate resin, polyester resin, alkyd resin, and vinyl chloride. Resin etc. can be used.

In addition, other coating materials may be used, such as pigments, curing agents, solvents, dispersants, viscosity modifiers, film forming aids, thickeners, antifoaming agents, leveling agents, anti-settling agents, anti-sag agents, plasticizers, etc. Additives such as preservatives, anti-mold agents, anti-algae agents, anti-bacterial agents, wetting agents, drying agents, dehydrating agents, matting agents, antifreeze agents, ultraviolet absorbers, antioxidants, light stabilizers, etc. It may be water-based, solvent-based, etc., and is not particularly limited.

The mixing ratio of the binder and particles in the coating material of the present invention is preferably 50 parts by weight or more and 3000 parts by weight or less (more preferably 100 parts by weight or more and 2000 parts by weight or less) per 100 parts by weight of the solid content of the binder. ).

For example, when gel-like particles are used as the particles, the gel-like particles are preferably 50 parts by weight or more and 500 parts by weight or less, more preferably 100 parts by weight or more and 400 parts by weight, based on 100 parts by weight of the solid content of the binder. The amount may be about 1 part by weight or less.

When solid particles are used as the particles, preferably 100 parts by weight or more and 3000 parts by weight or less, more preferably 300 parts by weight or more and 2000 parts by weight of the solid particles, based on 100 parts by weight of the solid content of the binder. It may be about the following.

<Coating method>
The coating method of the present invention can be mainly used for coating buildings, civil engineering structures, etc. Applicable base materials include, for example, gypsum board, plywood, concrete, mortar, brick, porcelain tile, fiber-containing cement board, cement calcium silicate board, slag cement perlite board, ALC board, siding board, extrusion board, and steel board. , plastic plates, etc. The surface of these base materials may have been subjected to some kind of surface treatment (e.g., sealer, surfacer, filler, putty, etc.), or may already have a paint film (e.g., old paint film with various paints, decorative paint materials, etc.). It may be formed.

The present invention is characterized in that the coating material is applied to the base material using a roller impregnated with the coating material, and in particular, the coating material is applied onto the base material by rolling the roller onto the base material. It is characterized by being transferred onto a material. By using the roller of the present invention, more coating material can be transferred to the base material by one rolling motion of the roller, and an excellent design can be formed evenly. In particular, the present invention can exhibit sufficient effects when using a coating material containing solid particles (preferably a coating material containing solid particles but not gel particles).
The transfer amount that can be transferred by one rolling of the roller is 0.5 kg/m ² or more and 2.0 kg/m ² or less, more preferably 0.8 kg/m ² or more and 1.5 kg/m ^{2 or} less. preferable.

In the present invention, the coating amount when coating the coating material may be set appropriately, but for example, when gel-like particles are used as the particles, the coating amount is preferably 0.2 to 3 kg. It may be about 0.3 to 2 kg/m ² , more preferably about 0.3 to 2 kg/m ² . Further, when solid particles are used as the particles, the coating amount may be preferably about 0.5 to 10 kg/m ² , more preferably about 0.8 to 4 kg/m ² .

Further, the viscosity of the coating material during coating may be adjusted as appropriate, but preferably, it may be adjusted to about 1 Pa.s or more and 300 Pa.s or less. The viscosity is a value measured using a BH type viscometer at a rotation speed of 2 rpm at a temperature of 23° C. and a relative humidity of 50% RH.

Further, the coating material may be cured by a known method, and is not particularly limited, but for example, a method of curing by applying heat, a method of curing without applying heat, or a method of curing by adding a catalyst etc. Examples include methods. In addition, in the method of curing by applying heat, the temperature may preferably be 40°C or higher and 200°C or lower, more preferably 50°C or higher and 120°C or lower. In addition, in a method of curing without applying heat (room temperature curing), it is preferable to cure at a temperature of 0° C. or higher and 40° C. or lower, more preferably 5° C. or higher and 35° C. or lower.

Furthermore, after the coating material is applied to the substrate, and before the coating material is completely cured, a roller not containing the coating material may be rolled on the surface of the coating material. By rolling the roller, the unevenness on the surface of the applied coating material can be moderated, and a more natural-looking design can be obtained.
Further, when rolling a roller not containing a coating material, the roller may be impregnated with water or a solvent in advance, or may be impregnated with nothing. As the roller to be rolled in this manner, the roller of the present invention may be used, or one or more types selected from wool rollers, sponge rollers, mastic rollers, etc. can also be used.

EXAMPLES Below, in order to clarify the effects of the present invention, Examples and Comparative Examples will be given and explained.

Coating materials 1 to 6 in which each particle was dispersed in an acrylic resin emulsion were prepared using the raw materials and formulations shown in Table 1 below. Note that all numerical values in Table 1 indicate parts by weight.

Next, rollers 1 to 24 shown in Table 2 were prepared as rollers. Note that the rollers 1 to 20 and 24 have a width of 175 mm, and the size and shape of the recesses are uniform. The roller 21 is a porous roller having no depressions. The roller 22 is a rubber-like pattern roller that has no depressions or holes and has an uneven surface. The roller 23 is a fibrous wool roller having no depressions or holes and having a hair length (thickness) of 10 mm.

(Evaluation experiment)
(Workability evaluation)
An acrylic resin undercoat material was applied to a 90 cm x 90 cm slate board (base material) at a coating amount of 0.2 kg/m ² and allowed to dry for 2 hours. Thereafter, the coating materials shown in Table 1 were applied using the rollers shown in Table 2 using the combinations shown in Table 3.
In the workability evaluation, when applying with a roller, the following four grades A to C and Z were evaluated. The results are shown in Table 3.
A: At least 1.2 kg/m ² of the coating material could be applied to the entire surface of the substrate in one application.
B: The coating material was able to be applied over the entire surface of the substrate in an amount of 1 kg/m ² or more and less than 1.2 kg/m ² in one application.
C: A coating material of 0.8 kg/m ² or more and less than 1 kg/m ² could be applied to the entire surface of the substrate in one application.
Z: Only less than 0.5 kg/m ² of the coating material could be applied to the entire surface of the substrate in one application.

(Finish evaluation)
An acrylic resin undercoat material was applied to a 90 cm x 90 cm slate board (base material) at a coating amount of 0.2 kg/m ² and allowed to dry for 2 hours. Then, using the combinations shown in Table 3, apply the coating materials shown in Table 1 at an application amount of 2.5 kg/ ^m2 using the roller shown in Table 2, dry for 24 hours, and visually check the surface finish. evaluated. The evaluation was made on the following four levels A to C and Z. The results are shown in Table 3.
A: There was no bias in the pattern over the entire surface, and an excellent design was confirmed.
B: The pattern was uniform over almost the entire surface, and an excellent design was confirmed.
C: Some deviations were observed in the pattern, but excellent designs were confirmed in most parts.
Z: The pattern was noticeably uneven. Or, the design could not be identified and was a single color.

From the evaluation results in Table 3 above, in the example, by applying the specified coating material using the specified roller, an excellent pattern design finish can be efficiently and easily achieved, and the workability and It was confirmed that the finish quality was at a level that would pose no practical problems. On the other hand, in the comparative example, because the prescribed rollers and coating materials were not used, no material was found that could achieve both workability and finish quality.
Regarding the porous roller 24, the workability was evaluated in the same manner as in Example 1 except that the porous roller 24 was used. As a result, 0.00% of the coating material was applied to the entire surface of the substrate in one application. It was possible to apply 7 kg/ ^m2 .

(Finish evaluation 2)
In Example 3, Example 10, Example 16, and Example 17, the following evaluations were performed.
An acrylic resin undercoat material was applied to a 90 cm x 90 cm slate board (base material) at a coating amount of 0.2 kg/m ² and allowed to dry for 2 hours. Thereafter, in the combinations shown in Table 3, the coating materials shown in Table 1 were applied at a coating amount of 2 kg/ ^m2 using the rollers shown in Table 2, and the roller 21 shown in Table 2 was further rolled on the surface of the coating materials. After drying for 2 hours, the surface finish was visually evaluated. The evaluation is the same as the finish evaluation.
The results were Example 3: AA, Example 10: A, Example 16: A, and Example 17: A, and an excellent design with a natural feel was confirmed. In particular, in Example 3, there was no bias in the pattern over the entire surface, and an excellent design with a more natural feel was confirmed (rating: AA).

Claims (3)

A coating method using a roller,
The roller is a porous roller,
The surface of the porous layer constituting the porous roller has a plurality of independent depressions, and the size of each depression is 2 mm or more and 30 mm or less,
The total area of the depressions on the surface of the porous roller is 10% or more and 80% of the entire roller surface,
The surface and inside of the porous layer constituting the porous roller have communicating pores, and the size of one hole is smaller than the size of one depression, and is 0.5 mm or more and 10 mm or less,
A coating method comprising applying a coating material containing particles having a size of 2 μm or more and less than 2 mm to a substrate using the roller. The coating method according to claim 1, wherein the depression has a depth of 1 mm or more and less than 25 mm. The coating method according to claim 1, wherein the thickness of the porous roller is 1 mm or more and less than 25 mm.