JP2023181280A - Patterned surface forming method - Google Patents

Abstract

To provide a method by which a border between a joint part and a pattern part becomes neat finish, and a joint pattern having excellent beauty appearance can be formed.SOLUTION: According to this method, the following processes (1) to (5) are performed: (1) a first process in which a primer material is coated, thereby forming a primer material layer; (2) a second process in which peelable joint material is placed on a surface of the primer material layer; (3) a third process in which a middle coating material is coated onto the surface obtained in the second process, thereby forming a middle coating material layer; (4) a fourth process in which a top coating material is coated onto a surface of the middle coating material layer, thereby forming a top coating material layer; and (5) a fifth process in which the joint material is removed. A color difference between the primer coating material layer and the middle coating material layer is so made as to be less than 10.SELECTED DRAWING: Figure 1

Description

The present invention relates to a method of forming a patterned surface. The present invention can be applied mainly to buildings, civil engineering structures, and the like.

BACKGROUND ART A method of providing a joint pattern such as a tile-like pattern is used to finish painting walls of buildings and civil engineering structures. According to such a method, a highly designed pattern surface can be formed.

As a method for forming a joint pattern, there is a method in which a bar-shaped or plate-shaped joint material is applied to the base and the joint material is removed after a finishing coat is applied. It is described in Publication No. 266517 and the like. According to the methods described in these patent documents, it is expected that a pattern surface full of design characteristics can be obtained due to the contrast between the joint portion and the pattern portion, the difference in level, etc.

Japanese Unexamined Patent Publication No. 2-292450 Japanese Patent Application Publication No. 10-266517

However, in reality, with the method described in the above-mentioned patent document, the coating material gets into the gap between the base and the joint material, resulting in a jagged border between the joint area and the pattern, resulting in an unsatisfactory finish and poor aesthetics. In some cases, it may not be possible to obtain a high pattern surface.

The present invention has been made in view of these problems, and it is an object of the present invention to provide a method for forming a joint pattern with excellent aesthetic appearance, with a clean finish at the boundary between the joint part and the pattern part. It is.

In order to achieve the above object, the present inventors conducted extensive research and found that after coating a base material with a base coat material and pasting a joint material, an intermediate coat material and a top coat material that meet specific conditions are sequentially applied. They came up with a method and completed the present invention.

That is, the present invention has the following features.
1. A method for forming a patterned surface having a joint pattern, the method comprising:
(1) A first step of coating the base material with an undercoat material to form an undercoat layer;
(2) a second step of installing a peelable joint material on the surface of the primer layer;
(3) a third step of coating the surface obtained in the second step with an intermediate coating material to form an intermediate coating material layer;
(4) a fourth step of coating a top coat material on the surface of the intermediate coat material layer to form a top coat material layer;
(5) a fifth step of removing the joint material;
and
The color difference between the undercoating material layer and the intermediate coating material layer is less than 10,
The intermediate coating material seals the gap between the primer layer and the joint material at the bottom of the joint material.
A method of forming a patterned surface characterized by the following.
2. The above-mentioned undercoat material is characterized in that it contains a resin component, a colored pigment, and a powder having an average particle diameter of 1 μm or more and a refractive index of 1.3 to 1.7.1. Method of forming the patterned surface described.
3. The intermediate coating material is characterized in that it contains a resin component and a colored pigment.1. or 2. The method for forming a patterned surface described in .
4. 1. The color difference between the undercoat material layer and the topcoat material layer is 10 or more. ~3. The method for forming a patterned surface according to any one of the above.

According to the present invention, the boundary between the joint part and the pattern part has a clean finish, and a joint pattern with excellent aesthetic appearance can be formed.

FIG. 1 is a schematic diagram showing an example of the present invention. It is a schematic diagram showing another example of the present invention.

a: Base material b: Undercoat material layer c: Peelable joint material d: Adhesive layer e: Intermediate coating material layers f, f1, f2: Top coat material layer g: Joint area h: Pattern area

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

The present invention is a method for forming a patterned surface having a joint pattern. FIG. 1 is a schematic diagram showing an example of the present invention. In the present invention, the joint portion is a portion of the pattern surface that forms a linear recess, and the undercoat layer b is visible at this joint portion. On the other hand, the pattern portion is a portion of the pattern surface that forms a convex portion, and the top coat material layer f is visible in this pattern portion (FIG. 1 (5)).

The present invention can be applied to, for example, the inner and outer walls, ceilings, floors, etc. of buildings, or the surfaces of civil engineering structures. Examples of the base material a constituting such a part include concrete, mortar, fiber-mixed cement board, cement calcium silicate board, slag cement perlite board, ALC board, siding board, extrusion board, gypsum board, perlite board, Examples include various base materials such as plywood, plastic plates, metal plates, wood boards, and ceramic tiles. These base materials may be subjected to some kind of surface treatment (e.g., cleaning treatment using detergent application, high-pressure washing, etc.; treatment for removing fragile parts using sander, peeling stick, etc.; coating with filler, surfacer, sealer, etc.; pasting mesh). They may be pre-colored with colored paint, etc., or may have a paint film already formed, wallpaper pasted, or a heat insulating layer laminated. etc. may be used.

First, as a first step, an undercoat material is applied to the above-mentioned base material a to form an undercoat material layer b (FIG. 1(1)). This undercoat layer b appears as joints g on the final pattern surface. Therefore, the color tone of the undercoat layer b may be set in accordance with the desired joint color.

As the undercoating material, for example, one containing a resin component and a colored pigment can be used. In such an undercoat material, the undercoat material layer b can be set to a desired color tone by appropriately adjusting the type of color pigment, mixing ratio, etc.

The resin component acts as a binder. Examples of the resin component include acrylic resin, urethane resin, acrylic urethane resin, epoxy resin, vinyl chloride resin, vinyl acetate resin, acrylic silicone resin, fluorine resin, polyvinyl alcohol, cellulose derivative, etc., or composites thereof. can be mentioned. These can be used alone or in combination of two or more. The form of the resin component is preferably a water-dispersible resin (resin emulsion) and/or a water-soluble resin. Among these, the water-dispersible resin can be produced by a one-stage or multi-stage (two-stage, three-stage or more) emulsion polymerization method.

The glass transition temperature (hereinafter also referred to as "Tg") of the resin component is preferably -30 to 50°C, more preferably -10 to 40°C. If Tg is within such a range, it is possible to ensure good performance in terms of stain resistance, crack resistance, adhesiveness and removability of joint material, etc. The Tg referred to here is a value determined by the Fox calculation formula from the types of monomers constituting the resin component and their composition ratios. In the present invention, "α to β" is synonymous with "above α and below β".

Such a resin component may have the property of causing a crosslinking reaction (crosslinking reactivity) after the coating film is formed. When the resin component has crosslinking reactivity, it is possible to improve the water resistance, weather resistance, adhesion, etc. of the undercoat layer b, and it is also suitable in terms of joint material removability, etc. Such a resin component may be one that causes a crosslinking reaction by itself, or one that causes a crosslinking reaction by a crosslinking agent that is mixed separately. Such crosslinking reactivity is, for example, between a carboxyl group and a metal ion, a carboxyl group and a carbodiimide group, a carboxyl group and an epoxy group, a carboxyl group and an aziridine group, a carboxyl group and an oxazoline group, a hydroxyl group and an isocyanate group, and a carbonyl group and a hydrazide group. , an epoxy group and an amino group, an aldo group and a semicarbazide group, a keto group and a semicarbazide group, and alkoxyl groups. A combination of such reactive functional groups can be used alone or in combination of two or more.

Examples of the color pigments include titanium oxide, zinc oxide, alumina, magnesium oxide, zirconium oxide, carbon black, ferric oxide (bengara), yellow iron oxide, iron oxide, ultramarine, cobalt green, iron-chromium composite. Inorganic coloring pigments such as oxides, manganese-bismuth composite oxides, manganese-yttrium composite oxides, manganese-iron-cobalt composite oxides; azo series, naphthol series, pyrazolone series, anthraquinone series, perylene series, quinacridone series, disazo series organic coloring pigments such as isoindolinone series, benzimidazole series, phthalocyanine series, and quinophthalone series; bright pigments such as aluminum pigments and pearl pigments; it is possible to use one or more of these. can.

The weight ratio of the colored pigment is preferably 3 to 300 parts by weight, more preferably 5 to 250 parts by weight, based on 100 parts by weight of the solid content of the resin component.

As the undercoating material, in addition to the resin component and the coloring pigment, it is more preferable to use a material containing powder or granules (hereinafter also simply referred to as "powder") with an average particle diameter of 1 μm or more and a refractive index of 1.3 to 1.7. It is. In such an undercoat material, the color tone can be easily set by the colored pigment, and the action of the powder ensures excellent performance in terms of adhesion and removability of the joint material c, finish quality of the joint part g, etc. becomes possible.

The average particle diameter of the granular material is 1 μm or more, preferably 2 to 100 μm, more preferably 3 to 70 μm, and still more preferably 4 to 50 μm. The average particle size means the 50% particle size measured by a centrifugal sedimentation type particle size distribution analyzer. Further, the refractive index of the granular material is preferably 1.3 to 1.7. Refractive index can be measured using an Abbe refractometer. In the present invention, by using a powder or granular material that satisfies these conditions, it is possible to improve the adhesion and removability of the joint material c, the finish quality of the joint part g, etc., while maintaining the color tone caused by the coloring pigment. . In particular, by setting the lower limit of the average particle diameter to the above value or more, advantageous effects can be obtained in terms of removability of the joint material c, finish quality of the joint part g, and the like. When the upper limit is below the above value, advantageous effects can be obtained in terms of the adhesiveness of the joint material c, the finish quality of the joint part g, etc.

Examples of granular materials include heavy calcium carbonate, agarite, light calcium carbonate, white carbon, talc, kaolin, clay, china clay, china clay, diatomaceous earth, barite powder, barium sulfate, precipitated barium sulfate, silica sand, Examples include silica powder, quartz powder, resin powder, and resin beads. These can be used alone or in combination of two or more.

The weight ratio of the powder is preferably 50 to 600 parts by weight, more preferably 100 to 500 parts by weight, and even more preferably 150 to 450 parts by weight, based on 100 parts by weight of the solid content of the resin component. By setting the lower limit of the weight ratio of the powder or granular material to the above value or more, advantageous effects can be obtained in terms of removability of the joint material c, finish quality of the joint part g, etc., and the upper limit thereof is below the above value. Accordingly, advantageous effects can be obtained in terms of the adhesiveness of the joint material c, the finish of the joint part g, and the weather resistance, cracking resistance, adhesion, etc. of the undercoat layer b.

The undercoat material can contain known additives in addition to the above components. Examples of such additives include aggregates, fibers, dispersants, emulsifiers, thickeners, coalescent agents, leveling agents, coupling agents, wetting agents, plasticizers, antifreeze agents, and pH adjusters. , a drying regulator, a preservative, a fungicide, an algaecide, an antibacterial agent, an antifoaming agent, an adsorbent, a deodorizing agent, an ultraviolet absorber, a light stabilizer, an antioxidant, a catalyst, a crosslinking agent, and the like. Particles other than those mentioned above (for example, powders and granules with an average particle diameter of less than 1 μm) may also be included as long as the effects of the present invention are not significantly impaired. The undercoat material can be manufactured by appropriately mixing the above components using a conventional method.

The undercoat material layer b is formed by coating the base material a with such an undercoat material. The method of applying the undercoat material is not particularly limited, and for example, methods such as spray painting, roller painting, brush painting, and troweling can be employed. In the present invention, among these, roller coating is preferred, and it is desirable to use a porous roller as the roller. When such a roller is used, appropriate undulations are formed on the surface of the undercoat layer b, making it possible to further improve the removability of the joint material c, the finish quality of the joint portion g, and the like.

A porous roller is, for example, one in which a porous layer is provided on the outer surface of a cylindrical core material, and the cylindrical core material is hollow so that a handle with a shaft can be attached thereto. It can be used by attaching a handle shaft to the cavity.

As the porous roller, for example, a roller having a sponge-like porous layer is preferable, and as the porous layer, one having communicating pores is preferable. The material of the porous layer is not particularly limited, but examples thereof include resins such as acrylic resin, polyurethane resin, polyester resin, polyethylene resin, and polypropylene resin, and it is preferable to use a porous sponge-like material made of these resins.

The pore diameter of such a porous layer is preferably 0.3 to 10 mm, more preferably 0.5 to 5 mm, and still more preferably 0.8 to 3 mm. Note that the pore diameter of each pore may be calculated by multiplying the maximum distance from the center of gravity of each pore by 2, and the pore diameter of the porous layer may be calculated by calculating the average value of the pores at 10 locations. Further, the thickness of the porous layer is preferably 1 to 25 mm, more preferably 2 to 20 mm. The width (length) of the porous roller is preferably 50 to 300 mm. The diameter of the porous roller (the value obtained by dividing the outer circumference of the porous layer by the circumference) is preferably 15 to 100 mm.

When applying the undercoat material, the viscosity can be adjusted appropriately by mixing a diluent such as water. The dilution ratio is preferably 0 to 10% by weight.

The coating amount of the undercoat material may be such that the base material a is hidden by the undercoat material layer b, but is preferably 0.1 to 1 kg/m ² , more preferably 0.2 to 0.6 kg/m It is ² . Drying of the undercoat material may preferably be carried out at room temperature (0 to 40°C). The drying time is preferably 3 hours or more, more preferably 6 hours or more. In the present invention, it is desirable to carry out the next step after drying the undercoat material layer b.

In the second step, a peelable joint material (hereinafter, "peelable joint material" is also simply referred to as "joint material") c is installed on the surface of the undercoat layer b (FIG. 1 (2)). The joint material c used here may be any material as long as it can be temporarily installed on the surface of the undercoat layer b, and for example, one that has adhesiveness at least on the surface that contacts the undercoat layer b can be used. As an example, FIG. 1 shows a joint material having an adhesive layer d. Such a joint material can be installed by pasting the adhesive layer d in contact with the undercoat layer b after the undercoat layer b has dried.

Examples of materials constituting the joint material c include rubbers such as silicone rubber, fluororubber, nitrile rubber, chloroprene rubber, butyl rubber, acrylic rubber, and SBR; polyester, polyurethane, acrylic, vinyl chloride, polyethylene, polypropylene, polystyrene, and polycarbonate. resin foams such as foamed polyurethane, foamed polyethylene, foamed polypropylene, and foamed polystyrene; These can be used alone or in combination of two or more.

The position, interval, etc. at which the joint material c is pasted may be determined depending on the desired joint pattern. For example, they can be pasted at equal intervals or randomly. Examples of patterns include tile-like patterns, brick-like patterns, geometric patterns, polka dot patterns, striped patterns, lattice patterns, swirl patterns, heraldic patterns, as well as designs of animals, plants, vessels, characters, etc. It is. In order to express these patterns, a combination of a plurality of linear joint materials may be used, or a planar paper pattern punched out according to the desired pattern shape may be used as the joint material. Before pasting the joint material c, marking etc. can be performed as appropriate in order to obtain a desired joint pattern. After pasting the joint material c, the surface of the joint material c can be pressed using a rubber roller, a plastic roller, a metal roller, etc., and the joint material c can be pressed onto the undercoat material layer b.

The width of the joint material c (width of the portion corresponding to the joint portion g) is preferably 1 to 20 mm. The height (thickness) of the joint material c is preferably 0.1 to 10 mm, more preferably 0.2 to 3 mm.

The joint material c may be one in which other layers are laminated as long as it has the adhesive layer d on the back surface. For example, it is also possible to use a material having an adhesive layer on the back side and a release paper on the front side. The adhesive layer may contain powder or the like.

In the third step, an intermediate coating material is applied to the surface obtained in the second step to form an intermediate coating material layer e (FIG. 1 (3)). In this third step, it is sufficient to apply the intermediate coating material at least to the boundary between the joint material c and the intermediate coating material layer e (the part where the side surface of the joint material c and the surface of the intermediate coating material layer e contact). , the intermediate coating material layer e may be a discontinuous coating film. However, in terms of improving work efficiency, it is possible to apply an intermediate coat to the entire surface of the base coat layer b to which the joint material c has been applied, that is, the entire surface including the part to which the joint material c has been applied. desirable.

As the intermediate coating material, one is used in which the color difference between the undercoat material layer b and the intermediate coating material layer e is less than 10 (preferably 8 or less, more preferably 5 or less, still more preferably 0 to 3). In the present invention, by applying an intermediate coating material that satisfies these conditions, the boundary between the joint part g and the pattern part h has a clean finish, and a joint pattern with excellent aesthetics can be formed. This effect is achieved because the gap between the base coat layer b and the joint material c is sealed by the intermediate coat material, which has almost the same color as the base coat layer b, and prevents the top coat material used in the subsequent process from entering the gap. It is thought that it is played. In the present invention, even if the composition of the undercoat material is adjusted to improve the removability of the joint material, and as a result, gaps are likely to be formed on the contact surface between the undercoat layer b and the joint material c, the aesthetic appearance is improved. Excellent joint patterns can be formed.

The color difference (ΔE) in the present invention is a value calculated based on the value (average value of arbitrary 10 points) of the color tone of each layer after drying measured with a color difference meter. Specifically, the color difference (ΔE _eb ) between the undercoat layer b and the intermediate coat layer e can be calculated using the following formula 1 from the L ^* value, a ^* value, and b ^* value of each layer.
<Formula 1> △E _eb = {(L ^* _e - L ^* _b ) ² + (a ^* _e - a ^* _b ) ² + (b ^* _e - b ^* _b ) ² } ^0.5
(In the formula, L ^* _e , a ^* _e , b ^* _e are the L ^* , a ^* , b ^* of the intermediate coat layer e, respectively. L ^* _b , a ^* _b , b ^* _b are the L of the undercoat layer b, respectively. ^* , a ^* , b ^* )

As the intermediate coating material, for example, one containing a resin component and a colored pigment can be used. In such an intermediate coating material, the intermediate coating material layer e can be set to a desired color tone by appropriately adjusting the type of color pigment, mixing ratio, etc.

As the resin component and coloring pigment in the intermediate coating material, the same ones as those explained for the undercoating material can be used.

The resin component in the intermediate coating material preferably has a Tg of -30 to 50°C, more preferably -10 to 40°C. Moreover, the resin component may have crosslinking reactivity. In such a case, when removing the joint material, the joint material c can be removed by cutting it with the width of the joint portion g, so the problem of the patterned portion h peeling off together with the joint material c is suppressed, and the joint material It becomes possible to efficiently remove c.

The weight ratio of the colored pigment in the intermediate coating material is preferably 3 to 300 parts by weight, more preferably 5 to 250 parts by weight, based on 100 parts by weight of the solid content of the resin component.

As the intermediate coating material, in addition to a resin component and a colored pigment, a material containing powder similar to the undercoating material can also be used. In such an intermediate coating material, it is easy to set the color tone using the colored pigment, and it is possible to ensure excellent performance in terms of removability of the joint material c, finish quality of the joint part g, etc.

The weight ratio of the powder in the intermediate coating material is preferably 10 to 500 parts by weight, more preferably 30 to 400 parts by weight, even more preferably 50 to 300 parts by weight, based on 100 parts by weight of the solid content of the resin component. By setting the lower limit of the weight ratio of the powder or granular material to the above value or more, when removing the joint material, it is possible to remove the joint material c so as to cut it by the width of the joint part g, so that the joint material c and the pattern part h can be removed together with the joint material c. The problem of peeling of the joint material is suppressed, the joint material c can be removed efficiently, and the intermediate coating material used to seal the gap at the bottom of the joint material is less noticeable, which has an advantageous effect on the finish of the joint part g, etc. can be obtained. By setting the upper limit of the weight ratio of the powder to the above value or less, the function of sealing the gap in the lower part of the joint material is fully exhibited, and the finish of the joint part g can be further improved.

It is desirable that the weight ratio of the granular material in the intermediate coating material is smaller than the weight ratio of the granular material in the undercoat material. Specifically, the weight ratio of the granular material in the intermediate coating material is more preferably 30 parts by weight or more smaller than the weight ratio of the granular material in the undercoat material, and even more preferably 50 parts by weight or more smaller. It is particularly desirable that the amount is less than 80 parts by weight. Further, it is desirable that the average particle diameter of all powder particles contained in the intermediate coating material is smaller than the average particle diameter of all powder particles contained in the undercoat material. In such a case, the above-mentioned effects are more likely to be obtained.

The intermediate coating material can contain known additives in addition to the above components. As such additives, for example, those similar to those explained in connection with the undercoat material can be used. Particles other than those mentioned above (for example, powders and granules with an average particle diameter of less than 1 μm) may also be included as long as the effects of the present invention are not significantly impaired. The intermediate coating material can be manufactured by suitably mixing the above components using a conventional method.

The intermediate coating material layer e is formed by coating the surface of the undercoating material layer b with such an intermediate coating material. The method of applying the intermediate coating material is not particularly limited, and for example, methods such as spray painting, roller painting, brush painting, and troweling can be employed. In the present invention, among these, roller coating is preferred, and it is desirable to use a fibrous roller as the roller. When such a fibrous roller is used, the function of sealing the gap in the lower part of the joint material can be sufficiently exhibited, and the finish of the joint part g can be further improved.

A fibrous roller, for example, has a fibrous layer on the outer surface of a cylindrical core material, and the cylindrical core material is hollow so that a handle with a shaft can be attached thereto. It can be used by attaching a handle shaft to the cavity.

The material of the fibrous layer is not particularly limited, but examples include pig hair, horse hair, goat hair, wool, raccoon hair, and synthetic fibers such as acrylic fibers, polyurethane fibers, polyester fibers, and polypropylene fibers. It will be done.

The thickness of the fibrous layer (dry thickness) is preferably 2 to 30 mm. Further, the length of the fibers constituting the fibrous layer is preferably 3 to 40 mm. A fibrous layer having the above-mentioned thickness can be obtained by suppressing the degree of freedom of the fibers in some way, such as by weaving these fibers together or by fixing them at two or more points.

The width (length) of the fibrous roller is preferably 50 to 300 mm. The diameter of the fibrous roller (the value obtained by dividing the outer circumference of the fibrous layer by the circumference) is preferably 15 to 100 mm.

When applying the intermediate coating material, the viscosity can be adjusted appropriately by mixing a diluent such as water. The dilution ratio is preferably 0 to 10% by weight.

The amount of intermediate coating material to be applied may be set within a range that achieves the gap sealing effect in the lower part of the joint material, preferably 0.03 to 0.5 kg/m ² , more preferably 0.05 to 0.5 kg/m 2 . It is 3 kg/ ^m2 . Drying of the intermediate coating material may preferably be carried out at room temperature (0 to 40°C). The drying time is preferably 1 hour or more, more preferably 2 hours or more. In the present invention, it is desirable to carry out the next step after drying the intermediate coating material layer e.

In the fourth step, a top coat material is applied to the surface of the intermediate coat material layer e to form a top coat material layer f (FIG. 1 (4)). In this fourth step, it is desirable to apply a topcoat material to the entire surface including the portion to which the joint material c is pasted. This can improve work efficiency. As the top coating material, for example, various materials exhibiting monochromatic or multicolored colors can be used.

As the topcoat material, it is desirable to use one in which the color difference between the undercoat material layer b and the topcoat material layer f is 10 or more (more preferably 12 or more, still more preferably 15 or more). In the present invention, even when a topcoating material that satisfies these conditions is applied, the boundary between the joint g and the pattern h has a clean finish, and the contrast between the joint g and the pattern h has been improved. A clear joint pattern with excellent aesthetics can be formed.

The color difference (△E _fb ) between the undercoat material layer b and the topcoat material layer f is calculated by the following formula 2 from the L ^* value, a ^* value, and b ^* value (average value of arbitrary 10 locations) of each layer. can do.
<Formula 2> △E={(L ^* _f - L ^* _b ) ² + (a ^* _f - a ^* _b ) ² + (b ^* _f - b ^* _b ) ² } ^0.5
(In the formula, L ^* _f , a ^* _f , b ^* _f are the L ^* , a ^* , b ^* of the top coat layer f, respectively. L ^* _b , a ^* _b , b ^* _b are the L of the base coat layer b, respectively. ^* , a ^* , b ^* )

As the top coating material, for example, one containing a resin component and a colored pigment can be used. In such a topcoat material, the topcoat material layer f can be set to a desired color tone by appropriately adjusting the type of color pigment, mixing ratio, etc.

As the resin component and coloring pigment in the top coat material, the same ones as those explained for the base coat material can be used.

The weight ratio of the colored pigment in the top coating material is preferably 3 to 300 parts by weight, more preferably 5 to 250 parts by weight, based on 100 parts by weight of the solid content of the resin component.

In addition to the above-mentioned components, the top coat material can contain the same powder or granules as the undercoat material, and can also contain known additives. As such additives, for example, those similar to those explained in connection with the undercoat material can be used. The top coating material can be manufactured by suitably mixing the above components using a conventional method.

The top coat material layer f is formed by coating such a top coat material on the surface of the intermediate coat material layer e. The method for applying the top coat material is not particularly limited, and for example, methods such as spray painting, roller painting, brush painting, and troweling can be employed.

When applying the top coat material, the viscosity can be adjusted appropriately by mixing a diluent such as water. The dilution ratio is preferably 0 to 20% by weight.

The amount of the top coat material to be applied may be set as appropriate within the range in which the desired pattern is formed, but is preferably 0.03 to 1 kg/m ² , more preferably 0.05 to 0.8 kg/m ² It is. Drying of the top coat material may preferably be carried out at room temperature (0 to 40°C). The drying time is preferably 1 hour or more, more preferably 2 hours or more.

In the fifth step, the joint material c is removed (FIG. 1 (5)). By removing the joint material c, a joint part g is formed, and a pattern surface with excellent aesthetic appearance is obtained, which has a difference in color tone and height between the joint part g and the pattern part h. The joint material c may be removed after the topcoat material is applied, and may be removed either before or after the topcoat material is dried. When removing the joint material c after the top coat material has dried, the joint material c can also be removed while pressing the patterned portion h using a presser or the like as appropriate.

After the fifth step, it is also possible to apply a clear coat material. Painting with such a clear coat material is suitable for improving weather resistance, water resistance, chemical resistance, durability, stain resistance, and the like. It is desirable that the clear coat material be applied to the entire surface including the joint areas g and pattern areas h. Examples of the clear coat material include acrylic resin clear coat material, urethane resin clear coat material, acrylic silicone resin clear coat material, silica clear coat material, fluororesin clear coat material, and the like. It is also possible to use a colored clear coat material as long as it does not impede the effects of the present invention.

In applying the clear coat material, a known method can be employed, such as various methods such as spray coating, roller coating, and brush coating. The coating amount of the clear coat material is preferably 0.01 to 0.5 kg/m ² , more preferably 0.03 to 0.4 kg/m ² . The clear coat material may preferably be dried at room temperature (0 to 40°C). The drying time is preferably 1 hour or more, more preferably 2 hours or more.

In the present invention, two or more types of top coating materials can be applied in the fourth step. That is, two or more types of top coat material layers can be laminated. FIG. 2 is a schematic diagram showing an example in which two types of top coat materials are applied and two types of top coat layers are laminated (top coat layer f1, top coat layer f2) in the fourth step. In addition, when using two or more types of top coat materials, the color tone of the top coat layer may be measured for a laminated coating film formed by the two or more types of top coat materials.

In the method shown in FIG. 2, the steps other than the fourth step are the same as those in FIG. 1, and the details are as described above.

In FIG. 2, in step 4-1, a first top coat material is applied to the surface of the intermediate coat layer e to form a first top coat layer f1 (FIG. 2 (4-1)). As the first top coating material, the same material as shown in FIG. 1 can be used, and the details are as described above.

Next, in step 4-2, a second top coat material is applied to the surface of the first top coat layer f1 to form a second top coat layer f2 (FIG. 2 (4-2)). In the present invention, it is desirable to apply the second top coat material after drying the first top coat layer f1.

The second top coat material is preferably one that can form a multicolored pattern from the viewpoint of improving aesthetics. As such a second top coat material, one in which liquid or gel-like color particles are dispersed in an aqueous medium can be used. As the second top coat material, for example, materials specified in JIS K5667:2003 can be used, and depending on the combination of colored particles and aqueous medium (color particles/aqueous medium) that constitute the second top coat material, oil-in-water type ( It is classified as O/W type) or water-in-water type (W/W type). In the present invention, remarkable effects can be obtained when the top coating material is a water-in-water type (W/W type). The weight ratio of colored grains and aqueous medium (colored grains: aqueous medium) is preferably 1:99 to 80:20 (more preferably 10:90 to 75:25, still more preferably 30:70 to 70:30). It is.

The colored particles in the second top coating material are particles in which a resin, a colored pigment, and a coloring material containing various additives as necessary are dispersed in an aqueous medium in a liquid or gel state. Examples of the resin in the coloring material include acrylic resin, urethane resin, vinyl acetate resin, acrylic vinyl acetate resin, acrylic urethane resin, acrylic silicone resin, fluororesin, polyvinyl alcohol, biogum, galactomannan derivative, alginic acid derivative, and cellulose derivative. etc. Since such resin is in the form of water-soluble resin and/or water-dispersible resin (resin emulsion), when the colorant is dispersed in an aqueous medium, it becomes a water-in-water type (W/W type) top coating material. .

Examples of the coloring pigment in the coloring material include those similar to the coloring pigments in the above-mentioned undercoat material, and one or more of these can be used.

The method of dispersing the coloring material into particles in an aqueous medium is not particularly limited, and any known method can be employed. Specifically, a method of dispersing the coloring material in an aqueous medium containing a dispersion stabilizer or the like can be adopted. The dispersion stabilizer is a component that stabilizes the colorant in the form of particles, and can be selected depending on the type of resin and colorant. Specific examples of the dispersion stabilizer include magnesium salts, calcium salts, barium salts, aluminum salts, sodium salts, potassium salts, borates, phosphates, and the like. In addition, for example, water-soluble polymers, clays, etc. can also be used as dispersion stabilizers. The aqueous medium can also contain the same resins as mentioned above (water-soluble resins, resin emulsions, etc.). In addition, when the aqueous medium contains a resin, there is a risk that the resin may seep into the gap below the joint material and affect the finish of the joint part g, but in the present invention, due to the action of the intermediate coating material, etc. The impact can be suppressed.

In the colorant and aqueous medium, known additives can be used as appropriate. Examples of such additives include extender pigments, aggregates, fillers, matting agents, fibers, gel forming agents, pigment dispersants, emulsifiers, thickeners, film forming aids, leveling agents, and coupling agents. agent, wetting agent, plasticizer, anti-freezing agent, pH adjuster, drying agent, preservative, anti-mold agent, anti-algae agent, anti-bacterial agent, anti-foaming agent, adsorbent, deodorizer, ultraviolet absorber, photostabilizer agents, antioxidants, catalysts, crosslinking agents, etc.

The particle size and shape of the colored particles can be set as appropriate. Specifically, the shape of the stirring blade during manufacturing, the size and position of the stirring blade with respect to the stirring tank, the rotation speed of the stirring blade, the viscosity of the coloring material, the method and concentration of dispersion stabilizer addition, the viscosity of the aqueous medium, etc. All you have to do is select and adjust. The particle size of the colored particles is preferably 0.01 to 10 mm (more preferably 0.1 to 8 mm).

As a coating method for the second top coat material, for example, spray coating, roller coating, brush coating, etc. can be adopted. Among these, for example, a porous roller can be used as the roller.

The second top coat material can be applied once or multiple times. The amount of second top coat material applied per coat is preferably 0.2 to 1.5 kg/m ² , more preferably 0.3 to 1.2 kg/m ² .

When applying the second top coat material, the viscosity can be adjusted appropriately by mixing a diluent such as water. The dilution ratio is preferably 0 to 10% by weight.

When using the second topcoat material, it is desirable that the color tone of the first topcoat material layer f1 is set to a color tone (co-color) similar to that of the second topcoat material layer f2. As a result, even if the first top coat layer f1 is visible between the color grains of the second top coat layer f2, there is no discomfort, and a finish with excellent aesthetics can be obtained.

Examples and comparative examples are shown below to further clarify the characteristics of the present invention.

・Undercoat material 1
Coloring pigments (carbon black, Bengara, yellow iron oxide , titanium oxide) 24 parts by weight, powder {calcium carbonate (average particle size 32 μm, refractive index 1.6) and kaolin (average particle size 5 μm, refractive index 1.6), average particle size of all powders 20 μm }320 parts by weight and other additives (film-forming aid, thickener, antifoaming agent, preservative, etc.) were uniformly mixed to produce dark gray undercoat material 1.

・Intermediate coating material 1
For 100 parts by weight of the solid content of the cross-linked reactive resin (same as above), 24 parts by weight of coloring pigments (carbon black, Bengara, yellow iron oxide, titanium oxide), powder {calcium carbonate (average particle size 4 μm, refractive index) 1.6) and kaolin (average particle size 5 μm, refractive index 1.6), average particle size of all powder and granules 5 μm} 170 parts by weight, and other additives (filming aid, thickener, antifoaming agent, Preservatives, etc.) were mixed uniformly to produce a dark gray intermediate coating material 1.

・Intermediate coating material 2
For 100 parts by weight of the solid content of the cross-linked reactive resin (same as above), 24 parts by weight of the coloring pigment (same as above), powder (calcium carbonate (average particle size 2 μm, refractive index 1.6) and kaolin (average particle size 8 μm) , a refractive index of 1.6), an average particle diameter of all powder particles of 4 μm}, 105 parts by weight, and other additives (same as above) were uniformly mixed to produce a dark gray intermediate coating material 2.

・Intermediate coating material 3
For 100 parts by weight of the solid content of the cross-linked reactive resin (same as above), 24 parts by weight of the coloring pigment (same as above), powder (calcium carbonate (average particle size 2 μm, refractive index 1.6) and talc (average particle size 12 μm) , refractive index 1.6), average particle diameter of all powder particles 8 μm}, 220 parts by weight, and other additives (same as above) were uniformly mixed to produce a dark gray intermediate coating material 3.

・Intermediate coating material 4
A dark gray intermediate coating material 4 was produced by uniformly mixing 24 parts by weight of the coloring pigment (same as above) and other additives (same as above) with 100 parts by weight of the solid content of the crosslinked reactive resin (same as above).

・Top coating material 1
62 parts by weight of coloring pigments (titanium oxide, carbon black, Bengara, yellow iron oxide), etc. per 100 parts by weight of solid content of cross-linked reactive resin {acrylic silicone resin emulsion (Tg 16°C, solid content 50% by weight)} Additives (aggregate, film-forming aid, thickener, antifoaming agent, preservative, etc.) were mixed uniformly to produce a light gray top coating material 1.

・Top coating material 2
Colored gel particles 1 (pale yellow gel particles; granulated colorant containing acrylic silicone resin emulsion, titanium oxide, yellow iron oxide, Bengara, and water as main components, particle size 1 to 3 mm) 15 parts by weight, gel 25 parts by weight of colored particles 2 (light gray gel-like particles; granulated colorant containing acrylic silicone resin emulsion, black iron oxide, titanium oxide, and water as main components, particle size 0.5 to 2 mm), gel-like color Particles 3 (brown gel-like particles; acrylic silicone resin emulsion, Bengara, yellow iron oxide, black iron oxide, titanium oxide, granulated coloring material whose main components are water, particle size 1 to 3 mm) 10 parts by weight, aqueous Top coating material 2 containing 50 parts by weight of a medium (acrylic silicone resin emulsion, aqueous medium containing water as a main component) was manufactured.

(Example 1)
Primer material 1 was applied to the entire surface of a 45 x 30 cm base material (slate board) at a coating amount of 0.3 kg/m ² using a porous roller (porous layer pore diameter 1 mm), and after drying for 16 hours. , a peelable joint material was attached. In addition, as the peelable joint material, a grid-like paper pattern (thickness 0.8 mm, width 6 mm) having an adhesive layer on the back side was used.

Next, intermediate coating material 1 was applied to the entire surface using a fibrous roller (fibrous layer thickness: 13 mm) at a coating amount of 0.1 kg/m ² and dried for 3 hours. Thereafter, topcoat material 1 was applied over the entire surface at a coating amount of 0.4 kg/m ² using a porous roller (porous layer pore diameter: 1 mm). After drying for 3 hours, top coating material 2 was applied twice over the entire surface using a porous roller (porous layer pore diameter: 3 mm) at a coating amount of 0.4 kg/m ² and dried for 24 hours. Thereafter, the peelable joint material was removed.

The color difference (ΔE _eb ) between the undercoat layer 1 (the coating film of the undercoat material 1) and the intermediate coating material layer 1 (the coating film of the intermediate coating material 1) was 0.4. The color difference (ΔE _fb ) between the undercoat material layer 1 and the topcoat material layer 1 (the coating film of the topcoat material 1) was 45.

The patterned surface obtained by the above process has a straight line finish with a clean boundary between the joints and the pattern, and the contrast between the joints and the pattern is clear, resulting in a joint pattern with excellent aesthetics. there were.

(Example 2)
Coating was carried out in the same manner as in Example 1, except that Intermediate Coating Material 2 was used instead of Intermediate Coating Material 1. The color difference (ΔE _eb ) between the undercoat material layer 1 and the intermediate coating material layer 2 (the coating film of the intermediate coating material 2) was 0.6.
Similar to Example 1, the patterned surface obtained in Example 2 has a clean linear finish with a clear boundary between the joint and the pattern, and the contrast between the joint and the pattern is clear, giving it a beautiful appearance. It had an excellent joint pattern.

(Example 3)
Coating was carried out in the same manner as in Example 1, except that Intermediate Coating Material 3 was used instead of Intermediate Coating Material 1. The color difference (ΔE _eb ) between the undercoat material layer 1 and the intermediate coating material layer 3 (the coating film of the intermediate coating material 3) was 0.5.
Similar to Example 1, the patterned surface obtained in Example 3 has a clean linear finish with a clear boundary between the joint and the pattern, and the contrast between the joint and the pattern is clear, giving it a beautiful appearance. It had an excellent joint pattern.

(Example 4)
Coating was carried out in the same manner as in Example 1, except that intermediate coating material 4 was used instead of intermediate coating material 1. The color difference (ΔE _eb ) between the undercoat material layer 1 and the intermediate coating material layer 4 (the coating film of the intermediate coating material 4) was 0.6.
The patterned surface obtained in Example 4 had a finish in which the boundary between the joint and the patterned portion was generally linear. The contrast between the joint area and the pattern area was clear, and the aesthetic appearance was also good.

(Comparative example 1)
When painting was carried out in the same manner as in Example 1, except for omitting the painting process of intermediate coating material 1, the resulting patterned surface had a jagged finish at the boundary between the joint and patterned parts, which was the same as in Example 1. It did not have the same aesthetic appeal.

Claims (4)

A method for forming a patterned surface having a joint pattern, the method comprising:
(1) A first step of coating the base material with an undercoat material to form an undercoat layer;
(2) a second step of installing a peelable joint material on the surface of the primer layer;
(3) a third step of coating the surface obtained in the second step with an intermediate coating material to form an intermediate coating material layer;
(4) a fourth step of coating a top coat material on the surface of the intermediate coat material layer to form a top coat material layer;
(5) a fifth step of removing the joint material;
and
The color difference between the undercoating material layer and the intermediate coating material layer is less than 10,
The intermediate coating material seals the gap between the primer layer and the joint material at the bottom of the joint material.
A method of forming a patterned surface characterized by the following. 2. The method for forming a patterned surface according to claim 1, wherein the undercoating material contains a resin component, a colored pigment, and a powder having an average particle diameter of 1 μm or more and a refractive index of 1.3 to 1.7. 3. The method for forming a patterned surface according to claim 1, wherein the intermediate coating material contains a resin component and a colored pigment. 4. The method for forming a patterned surface according to claim 1, wherein the color difference between the undercoat material layer and the topcoat material layer is 10 or more.

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