JP4895540B2 - Pressing tool and pattern forming method using the same - Google Patents

Description

  The present invention relates to a pressing tool used when forming a concavo-convex pattern on a building interior / exterior surface and the like, and a pattern forming method using the pressing tool.

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

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

Japanese Patent Laid-Open No. 10-266517

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

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

That is, the present invention has the following characteristics.
1. In the pattern forming method of forming a concavo-convex pattern by pressing the coating film using a pressing tool while the coating material is undried after coating the coating material on the substrate,
As the coating material, an aqueous resin and a granular material are essential components, and the granular material is contained in 30 to 80% by weight in the coating material, and 30% by weight or more of the granular material has a particle diameter of 50 μm or more. A 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 used.
As the pressing tool, the pressing surface of the pressing tool is assumed to be a virtual polygon, and an arbitrary pattern of protrusions is provided inside the virtual polygon, and each side of the virtual polygon has a protruding edge. And
In a region adjacent to the pressing surface, when the pressing surface is rotated around the center point of the virtual polygon, a pressing tool is used in which protruding ridges are provided so that the protruding rims coincide on the overlapping sides. ,
In the area | region adjacent to the area | region which pressed, the pressing tool is rotated and pressed so that a convex edge part may correspond, The pattern formation method characterized by the above-mentioned.
2. In the pattern forming method of forming a concavo-convex pattern by pressing the coating film using a pressing tool while the coating material is undried after coating the coating material on the substrate,
The above coating material is applied to the base material so that the average film thickness is 0.5 to 15 mm,
1. The coating film is pressed using a pressing tool provided with a ridge having a width of 0.5 times or more of the average film thickness of the coating material as the pressing tool. The pattern formation method as described in any one of.

  In the present invention, the degree of freedom of the pattern to be formed is high, and a novel uneven pattern surface can be obtained. In particular, in the present invention, since a pressing tool that satisfies a specific condition is used, a concavo-convex pattern with changes can be easily formed. Furthermore, unlike the conventional method, the present invention does not use joint materials, and therefore can contribute to waste reduction.

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

[Pressing tool]
As for the pressing tool used in the present invention, the pressing surface assumes a virtual polygon, and a convex strip of an arbitrary pattern is provided inside the virtual polygon, and a convex edge is provided on each side of the virtual polygon. In the area adjacent to the pressing surface, when the pressing surface is rotated around the center point of the virtual polygon, the protruding ridge is provided so that the protruding rims coincide on the overlapping sides. It is made.

  An example of the pressing tool in the present invention is shown in FIG. In the pressing tool of FIG. 1, the bottom surface of the substrate A is the pressing surface. A convex strip C is attached to the pressing surface, and a handle B is attached to the front side of the substrate A. In the pressing tool of FIG. 1, the handle B is attached for the purpose of efficiently performing the pressing operation. However, if the pressing can be performed only by the substrate A, the handle B can be omitted. It is also possible to attach the handle B directly to the ridge C. If the shape or the like of the ridge C is devised, both the substrate A and the handle B can be omitted. The height of the ridge may be larger than the average film thickness of the coating material.

  FIG. 2 is a diagram illustrating a pressing surface of the pressing tool in FIG. 1. The pressing tool in FIG. 1 assumes a square as a virtual polygon (dotted line portion D in FIG. 2), and a pattern in which four ridges are combined is provided therein. On each side of the virtual square, there are ridge edges 1-4.

FIG. 3 shows a state in which the pressing surface of the pressing tool (FIG. 2) shown in FIG. 1 is rotated around the center point 5 of the virtual polygon in an area adjacent to the pressing surface.
FIG. 3A shows a case where the pressing surface is rotated 90 ° rightward in the adjacent region on the right side of the pressing surface. In (a), the edge 2 and the edge 3 coincide on the overlapping side.
FIG. 3 (a) shows a case where it is rotated 180 °, FIG. 3 (c) shows a case where it is rotated 270 °, and FIG. 3 (d) shows a case where it is rotated 360 °. In these (a) to (d), the protruding edge portions all coincide on the side.
In the pressing surface of FIG. 2, there are a total of 16 combinations of edges, but in any combination, the protruding edges match.

  In this way, the pressing tool in the present invention is provided with the ridges so that the ridge edges match on each side. By providing the ridges under such conditions, it becomes possible to easily form a continuous uneven pattern with changes.

In addition, although the case where it has one edge part on each edge | side was shown in FIG. 2, as long as an edge part corresponds at the time of rotation, two or more edges may be provided in one side. An example is shown in FIG.
Moreover, although it is desirable that the width | variety in each edge part of the protruding item | line C is the same, the width | variety of the protruding item | line C in the inside of a virtual polygon may be changing.

  The material of the protrusion C is not particularly limited, and for example, plastic, wood, metal or the like can be used. The portion where the ridge C is in contact with the coating material may be treated with a release agent or the like as necessary.

  In FIG. 1, the case where a square is used as the virtual polygon is given, but other than this, for example, an isosceles triangle (FIG. 7), a rectangle, a trapezoid, a parallelogram, a rhombus, etc. The square can also be a virtual polygon. Considering the degree of freedom of the pattern, work efficiency, and the like, regular polygons such as regular triangles, squares, regular hexagons, and the like are preferable.

  By satisfying the above conditions, the pressing tool in the present invention can design a free pattern inside the virtual polygon, and can also create a novel pattern.

[Pattern formation method]
The pattern formation according to 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, a coating material is first applied to the base material as described above. As the coating material, various coating materials can be used as long as the concave-convex pattern can be formed by pressing, and among them, various coating materials can be used. A coating material having a body content of 30 to 80% by weight in the coating material, a solid content of the coating material of 50 to 95% by weight, a viscosity of 50 to 1500 Pa · s, and a thixotropy index of 3.0 or more can be preferably used. By using such a coating material, it is difficult for the coating material to adhere to the pressing tool when the pressing tool is pulled away from the coating material, and the shape of the coating film obtained by pressing does not collapse, even after pressing The shape can be maintained.

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

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

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

  In the coating material, if necessary, thickeners, leveling agents, wetting agents, plasticizers, film-forming aids, antifreezing agents, pH adjusting agents, preservatives, antifungal agents, antialgae agents, antibacterial agents, 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 coating material is usually 50 to 95% by weight (preferably 60 to 92% by weight, more preferably 65 to 90% by weight). By preparing the coating material to such a high solid content, a stable pattern can be formed by pressing. Moreover, thinning of the coating film can be suppressed, and three-dimensional design properties can be sufficiently expressed. When the solid content of the coating material is too low, it is difficult to form a concave portion by pressing, and it is difficult to obtain a clear concavo-convex feeling.

The viscosity of the coating material is usually 50 to 1500 Pa · s, preferably 100 to 1000 Pa · s, more preferably 200 to 800 Pa · s. Further, the thixotropy index (TI value) of the coating material is usually 3.0 or more, preferably 4.0 to 8.0, more preferably 5.0 to 7.0. By adjusting the viscosity and TI value of the coating material within such ranges, workability during pressing, finishing of the pressing portion, and the like can be improved. When the viscosity of the coating material is too low, the shape of the coating film changed by pressing is not maintained, and the boundary between the concave portion and the convex portion becomes unclear. If the viscosity of the coating material is too high, the pressing operation cannot be performed efficiently. When the TI value of the coating material is too low, the coating material is easily caught by the pressing tool. Moreover, the coating film shape changed by pressing is not maintained, and the boundary between the concave portion and the convex portion becomes unclear.
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). ℃.)

  Such a coating material is suitable for a wall surface or the like because dripping or the like does not occur even on a vertical surface.

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

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

  Next, after the coating material is applied, the coating material is pressed using the above-described pressing tool while the coating material is undried. In this pressing step, the pressing may be sequentially performed in the surface direction. At this time, in the area adjacent to the area where the pressing is performed first, the pressing tool can be rotated and pressed so that the convex edge portion of the pressing tool is matched. By sequentially pressing while rotating the pressing tool in this way, a concavo-convex pattern with changes can be easily formed.

  FIG. 4 shows an example of a pattern surface formed by rotating and pressing the pressing tool shown in FIG. Since the pressing tool in FIG. 1 is based on a square, it can be pressed continuously in the vertical and horizontal directions. At this time, in each region, when the edge 1 is set upward, the edge 2 is set upward, the edge 3 is set upward, and the edge 4 is set upward, any total of 4 patterns It can be selected and pressed. In the adjacent regions, the convex edge portions match, so that a continuous pattern can be obtained as a whole.

  Although FIG. 4 shows the case where one type of pressing tool is used, a combination of a plurality of pressing tools having different protruding patterns can be used as long as the protruding edges match when rotated. Can also be used.

FIG. 6 shows an example of a pattern surface formed by rotating and pressing the pressing tool shown in FIG.
FIG. 8 shows an example of a pattern surface formed by rotating and pressing the pressing tool shown in FIG. The pressing tool of FIG. 7 is based on an isosceles triangle, and when rotated in an adjacent region, the protruding rims coincide on the overlapping (equal length) sides.

  The width of the ridges of the pressing tool is desirably 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 coating material. By using a pressing tool with such a ridge width, the coating material around the pressing part is appropriately raised, the boundary between the concave part (pressing part) and the convex part (non-pressing part) becomes clear, and the uneven pattern has a sharpness. Can be obtained. Although the upper limit of the width of the ridge is not particularly limited, it is usually sufficient if it is within a range of 50 times or less with respect to the average film thickness of the coating material.

  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 ridge portion 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.

In the present invention, after the coating material is dried, a clear paint, a water repellent or the like can be applied as necessary. Among these, examples of the clear paint include acrylic resin-based paints, urethane resin-based paints, epoxy resin-based paints, acrylic silicon resin-based paints, and fluororesin-based paints. Such a clear paint can also adjust the degree of gloss by blending a matting agent or the like. Moreover, as long as the effect of this invention is not inhibited, 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: Titanium oxide dispersion (solid content 70% by weight, particle size 0.3 μm)
・ External pigment: heavy calcium carbonate (particle size 5-10 μm)
-Aggregate: Cold water stone (particle diameter 0.1-0.3mm)
・ Film-forming auxiliary: 2,2,4-trimethyl-1,3-pentanediol monoisobutyrate ・ Thickener: Cellulosic thickener (solid content: 100% by weight)
-Antifoaming agent: Silicone-based antifoaming agent (solid content 50% by weight)

Example 1
40 parts by weight of color pigment, 150 parts by weight of extender pigment, 280 parts by weight of aggregate, 14 parts by weight of film-forming aid, 60 parts by weight of water, and 5 parts by weight of thickener with respect to 200 parts by weight of resin A coating material was produced by uniformly mixing 3 parts by weight of an antifoaming agent by a conventional method. In this coating material, the powder and particle ratio 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 obtained by the above method was applied to a slate plate (90 × 90 cm) that had been previously sealed with a sealer. At this time, the average film thickness of the undried coating film (calculating the average value at 10 locations) was 5 mm. Next, using the pressing tool having the shape shown in FIG. 1 (the shape of the substrate: a square with a side of 30 cm, the width of the ridge: 10 mm, the height of the ridge: 30 mm) The surface was pressed continuously and dried for 24 hours. As a result, the uneven pattern shown in FIG. 4 could be obtained. Moreover, in the finished appearance, the boundary between the pressing portion and the non-pressing portion was clear. 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 press surface of a pressing tool (FIG. 1). It is a figure which shows the state which rotated the virtual polygon about the center point of the virtual polygon in the area | region adjacent to a press surface about the pressing tool of FIG. It is a figure which shows an example of the pattern surface formed with the pressing tool (FIG. 1). It is a figure which shows the press surface of a pressing tool. It is a figure which shows an example of the pattern surface formed with the pressing tool (FIG. 5). It is a figure which shows the press surface of a pressing tool. It is a figure which shows an example of the pattern surface formed with the pressing tool (FIG. 7).

Explanation of symbols

A: Substrate B: Handle C: Convex D: Virtual polygons 1-4: Edge 5: Center point

Claims (2)

In the pattern forming method of forming a concavo-convex pattern by pressing the coating film using a pressing tool while the coating material is undried after coating the coating material on the substrate,
As the coating material, an aqueous resin and a granular material are essential components, and the granular material is contained in 30 to 80% by weight in the coating material, and 30% by weight or more of the granular material has a particle diameter of 50 μm or more. A 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 used.
  As the pressing tool, the pressing surface of the pressing tool is assumed to be a virtual polygon, and an arbitrary pattern of protrusions is provided inside the virtual polygon, and each side of the virtual polygon has a protruding edge. And
  In a region adjacent to the pressing surface, when the pressing surface is rotated around the center point of the virtual polygon, a pressing tool is used in which protruding ridges are provided so that the protruding rims coincide on the overlapping sides. ,
  In the area | region adjacent to the area | region which pressed, the pressing tool is rotated and pressed so that a convex edge part may correspond, The pattern formation method characterized by the above-mentioned. In the pattern forming method of forming a concavo-convex pattern by pressing the coating film using a pressing tool while the coating material is undried after coating the coating material on the substrate,
The above coating material is applied to the base material so that the average film thickness is 0.5 to 15 mm,
 The pattern formation according to claim 1, wherein the coating film is pressed using a pressing tool provided with a ridge having a width of 0.5 times or more of the average film thickness of the coating material as the pressing tool. Method.

Images