JP4877719B2 - Pattern formation method - Google Patents

Description

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

  Conventionally, when a building interior / exterior surface or the like is painted, a paint generally called a flat paint is often used. A typical example of the flat paint is a paint defined in JIS K5663 “Synthetic Resin Emulsion Paint”. With such a flat paint, it is possible to form a coating film with a reduced surface gloss, and to obtain a calm finish. Various colors can be expressed by toning with a pigment. However, the color obtained by the flat paint is usually a single color.

On the other hand, a method has been proposed in which shades of color appear on the surface by laminating two kinds of coating films.
For example, in Patent Document 1, a semi-transparent paint different in color from the uneven surface is applied to the colored uneven surface, and the semi-transparent paint is accumulated in the recessed portion, so that the convex portion and the recessed portion have different color shades. The method of making is described.
Patent Document 2 discloses that a base material containing aggregate is sprayed on a base to form irregularities, and then a semi-fluid coating is applied with a semi-fluid coating so that the irregular surface of the underlying layer is almost smooth, A method for forming a shading pattern is described.

Japanese Utility Model Publication No. 49-75610 JP-A-11-62162

However, in the method described in the above patent document, the uneven pattern is limited because the uneven surface is formed by spraying or the like. Therefore, there is a limit to obtain a pattern with a high degree of freedom even on the finished surface finally obtained.
The present invention has been made in view of the above-described problems, and an object of the present invention is to propose a pattern forming method with a high degree of freedom of a pattern to be formed and a novel pattern surface can be obtained.

  As a result of intensive studies to achieve the above-mentioned object, the present inventor first formed the first coating material, and then formed irregularities on the undried coating film using a specific pressing tool, and then formed. The inventors have conceived a method of filling and coating a second coating material having a color different from that of the first coating material using the unevenness, and have completed the present invention.

That is, the present invention has the following characteristics.
1. (1) An aqueous resin and powder are essential components, the powder is contained in an amount of 30 to 80% by weight, and 30% by weight or more of the powder is a particle diameter of 50 μm or more. The first coating material having a solid content of 50 to 95% by weight, a viscosity of 50 to 1500 Pa · s, and a thixotropy index of 3.0 or more is applied to the substrate so that the average film thickness is 0.5 to 15 mm. The process of
(2) While the first coating material is undried, using a pressing tool having a width of 0.5 times or more the average film thickness of the first coating material (hereinafter referred to as “first” A step of partially pressing the "coating film" to give irregularities to the first coating film,
(3) After the first coating film is dried, the second coating material, which is different from the first coating material and has a concealment rate of 20 to 95%, is filled and applied to the recesses of the first coating film using scissors. Process,
The pattern formation method characterized by having.

According to the present invention, the degree of freedom of a pattern to be formed is high, and a novel pattern surface can be obtained.
In the present invention, the shape of the pressing tool is appropriately set, the pressing pattern and the like are variously changed, and the hue and concealment of the coating material are adjusted, thereby forming an unprecedented pattern surface. Can do.

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

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

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

  The 1st coating material used by this invention has aqueous resin and a granular material as an essential component. Among these, the aqueous resin acts as a binder, and a water-dispersible resin and / or a water-soluble resin can be used. Examples of the resin include acrylic resin, urethane resin, vinyl acetate resin, silicon resin, fluorine resin, ethylene resin, polyester resin, alkyd resin, vinyl chloride resin, epoxy resin, acrylic / vinyl acetate resin, acrylic / urethane resin , Acrylic / silicone resin, polyvinyl alcohol, cellulose derivatives and the like, and one or more of these can be used.

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

  Examples of the powder and granule include: cryolite, kaolin, clay, porcelain clay, china clay, diatomaceous earth, talc, barite powder, quartz sand, gravel, glass beads, resin beads, metal grains, or rocks, glass, ceramics, shells, grilled Examples include aggregates such as aggregates, concrete, mortar, plastic, rubber and other crushed products. Colored ones can also be used. In addition, coloring pigments, extender pigments, and hollow particles that can be normally used for coating materials can also be used as powders.

  Examples of 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.

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

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

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

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

  In the first coating material, thickeners, leveling agents, wetting agents, plasticizers, film-forming aids, antifreezing agents, pH adjusting agents, antiseptics, antifungal agents, algaeproofing agents, antibacterial agents as necessary Various additives such as a dispersant, an antifoaming agent, a fiber, an adsorbent, an ultraviolet absorber, an antioxidant, a catalyst, and a crosslinking agent may be mixed. Moreover, water can also be mixed suitably.

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

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

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

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

  Then, after the coating of the first coating material, the coating film is pressed with a pressing tool having a width of 0.5 times or more of the average film thickness of the first coating material while the coating film is undried. . In the present invention, by using a pressing tool having such a specific shape, a concave portion corresponding to the shape of the pressing tool is formed at the time of pressing, and a coating material around the pressing portion is appropriately raised to form a convex portion. The shape is retained even after pressing. The convex portions formed in this way greatly contribute to the improvement of the wrinkling workability in the subsequent process. In addition, the width | variety of the pressing tool in this invention is a dimension of the short direction of a pressing tool bottom face.

  As the pressing tool, one having a width of 0.5 times or more (preferably 1.0 times or more, more preferably 1.5 times or more) with respect to the average film thickness of the first coating material can be used. Although the upper limit of the width | variety of a pressing tool is not specifically limited, Usually, it should just exist in the range of 50 times or less with respect to the average film thickness of a 1st coating material.

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

  Another example of the pressing tool is shown in FIG. The pressing tool in FIG. 3 has a trapezoidal bottom surface (FIG. 4), and its width gradually changes. In the case of such a pressing tool, it is sufficient that the width is larger than the average film thickness of the coating material at least in the maximum width portion (width 12), but even in the minimum width portion (width 13). If is larger than the average film thickness of the coating material, a more desirable effect can be obtained.

  In addition, in the present invention, pressing tools having various shapes as shown in FIG. 5 can be used. Moreover, what has the width | variety from which the bottom face and upper surface of a pressing tool differ can be used.

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

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

After drying the first coating film, a second coating material having a different color from the first coating material and having a low hiding property is filled and applied to the concave portion of the first coating film using scissors. In this process, since the convex part of the first coating can be applied as a fulcrum, the second coating material can be applied with a film thickness corresponding to the height of the convex part, and the efficiency and stabilization of the painting work Can be achieved.
Moreover, on the finally obtained coating surface, the hue of the first coating material appears strongly at the convex portion of the first coating film, and the hue of the second coating material appears strongly at the region corresponding to the concave portion of the first coating film. It becomes. In an intermediate region between the convex portion and the concave portion, the hue becomes intermediate between the first coating material and the second coating material. When this intermediate region has an inclination, a pattern in which the hue gradually changes between the convex portion and the concave portion can be obtained.
In the present invention, a novel concavo-convex pattern surface that has not been obtained in the past can be obtained by variously combining the hue of the first coating film, the hue of the second coating film, and the uneven shape of the first coating film.

  As the second coating material, various coating materials can be used as long as the hue is different from that of the first coating material. Usually, an aqueous resin may be used as a binder, and a color imparted with a granular material may be used. As this aqueous resin and granular material, the same thing as a 1st coating material can be used.

The concealment rate of the second coating material is usually 20 to 95% (preferably 30 to 90%, more preferably 30 to 80%). If the concealment rate is within such a range, it is possible to sufficiently express the versatility due to the combined action with the first coating film.
In addition, the concealment rate in this invention is the value measured about the coating film with a dry film thickness of 150 micrometers using the concealment rate test paper according to JISK5600-4-1: 1999 "concealment power".

  The mixing ratio of the aqueous resin and the granular material in the second coating material may be set as appropriate so that the concealment ratio is within the above range, but the granular material is usually added to 100 parts by weight of the solid content of the aqueous resin. The amount may be about 10 to 800 parts by weight (preferably 30 to 600 parts by weight).

  What is necessary is just to perform the drying after the coating of a 2nd coating material at normal temperature (about 5-40 degreeC). When drying at room temperature, a cured coating film can usually be formed by providing a drying time of 24 hours or longer after application. In addition, drying of a coating material can also be performed under high temperature as needed.

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

Examples are given below to clarify the features of the present invention.
In the production of the coating material, the following raw materials were used.
-Resin: acrylic resin emulsion, solid content 50% by weight, minimum film-forming temperature 20 ° C)
Coloring pigment 1: Titanium oxide dispersion (solid content 70% by weight, particle size 0.3 μm)
Coloring pigment 2: Petrole dispersion (solid content 50% by weight, particle size 0.3 μm)
-Extender pigment 1: heavy calcium carbonate (particle size 5-10μm)
-Extender pigment 2: heavy calcium carbonate (particle size 20-25μm)
-Aggregate 1: Cold water stone (particle diameter 0.1-0.3mm)
Aggregate 2: colored silica sand (brown / red / light yellow mixture, particle size 0.1 to 0.2 mm)
-Aggregate 3: Natural mica (particle diameter 0.8-1.2mm)
-Aggregate 4: Shell pieces (particle diameter 2-4mm)
-Film-forming aid 1: 2,2,4-trimethyl-1,3-pentanediol monoisobutyrate-Film-forming aid 2: Ethylene glycol monobutyl ether-Thickener 1: Cellulosic thickener (solid content 100% by weight)
-Thickener 2: Polyurethane thickener (solid content 50% by weight)
-Antifoaming agent: Silicone-based antifoaming agent (solid content 50% by weight)

Example 1
40 parts by weight of color pigment 1, 10 parts by weight of color pigment 2, 150 parts by weight of extender pigment 1, 280 parts by weight of aggregate 1, 14 parts by weight of film-forming aid 1 and 200 parts by weight of resin 60 parts by weight, thickener 1 5 parts by weight, and antifoaming agent 3 parts by weight were uniformly mixed by a conventional method to prepare coating material A. In this coating material A, the proportion of the powder in the coating material was 61% by weight, the solid content was 75% by weight, the viscosity was 500 Pa · s, and the TI value was 5.5.

  The coating material A was troweled on a slate plate (90 × 90 cm) that had been previously sealed with a sealer. At this time, the average film thickness of the undried coating film (calculating the average value at 10 locations) was 5 mm. Next, the surface of the undried coating film was continuously pressed using a pressing tool (width 10 to 30 mm, height 30 mm, length 200 mm) shown in FIG. 3 to form the pattern shown in FIG. 6. .

  After drying for 24 hours, the coating material B was applied by coating so that the coating film recesses of the coating material A were filled. The coating material B used here is 200 parts by weight of resin, 350 parts by weight of extender pigment 2, 150 parts by weight of aggregate 1, 14 parts by weight of film-forming aid 1, and 5 parts by weight of thickener 1. Part and 3 parts by weight of an antifoaming agent were mixed, and the concealment ratio of the coating film was 74%.

  The specimen obtained by the above method had a finished appearance of a color in which light red, white, and an intermediate color thereof were mixed. The painting work and drying were all performed at a temperature of 23 ° C. and a relative humidity of 50%.

It is a figure which shows an example of a pressing tool. It is a figure which shows the bottom face of a pressing tool (FIG. 1). It is a figure which shows another example of a pressing tool. It is a figure which shows the bottom face of a pressing tool (FIG. 3). It is a figure (bottom view) which shows another example of a pressing tool. It is a figure which shows an example of the uneven | corrugated provision with a pressing tool.

Explanation of symbols

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

Claims (1)

(1) An aqueous resin and powder are essential components, the powder is contained in an amount of 30 to 80% by weight, and 30% by weight or more of the powder is a particle diameter of 50 μm or more. The first coating material having a solid content of 50 to 95% by weight, a viscosity of 50 to 1500 Pa · s, and a thixotropy index of 3.0 or more is applied to the substrate so that the average film thickness is 0.5 to 15 mm. The process of
(2) While the first coating material is undried, using a pressing tool having a width of 0.5 times or more the average film thickness of the first coating material (hereinafter referred to as “first” A step of partially pressing the "coating film" to give irregularities to the first coating film,
(3) After the first coating film is dried, the second coating material, which is different from the first coating material and has a concealment rate of 20 to 95%, is filled and applied to the recesses of the first coating film using scissors. Process,
The pattern formation method characterized by having.

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