JP6456755B2 - Film formation method - Google Patents

Description

  The present invention relates to a novel film forming method.

Conventionally, natural stone materials such as marble have been used as one of the wall materials in the interior and exterior of buildings. Such natural stone has a colorful pattern and is excellent in aesthetics. However, since the wall material obtained by processing natural stone is generally heavy and thick, the load on the base material tends to increase. In addition, such a wall material has a disadvantage that it is expensive.
Therefore, various methods for forming a pattern similar to natural stone such as marble have been proposed. For example, in Patent Document 1, a stone-like coating material including an aggregate obtained by pulverizing natural stone or ceramic with a particle size of 0.1 to 3 mm is applied to an acrylic resin emulsion to form a stone-like finish layer. The finishing method is described.

However, in such a construction method, in order to obtain a finish with natural stone-like texture, profound feeling, etc., the thickness of the stone-like finishing layer is required to be several mm or more, and the stone-like coating containing aggregate It is necessary to apply at least about 4 to 5 kg / m ^{2 of the} material.

JP 2004-189909 A

  The present invention has been made in view of such problems, and provides a film forming method capable of obtaining a finish with natural stone-like texture, profound feeling, etc. while reducing the amount of coating material used. It is the purpose.

  In order to solve such a problem, as a result of intensive studies, the present inventors have conceived a film forming method in which a step of forming a specific first covering material and a step of forming a specific second covering material are performed in that order. The present invention has been completed.

That is, the film forming method of the present invention has the following characteristics.
1. A method of forming a film of a first covering material on a base material, a step of forming a film of a second covering material, and a film forming method for performing in that order,
The coating of the first covering material is formed by spraying,
The first covering material includes a transparent granular material (1a) having a particle diameter of 0.05 to 5 mm, a resin component (1b), and a coloring pigment (1c), and the solid content weight ratio thereof is the transparent granular material. 1 to 50 parts by weight of the resin component (1b) and 0.1 to 20 parts by weight of the color pigment (1c) with respect to 100 parts by weight of the body (1a),
The amount of the first coating material used (in terms of solid content) is 0.4 to 3 kg / m ² .
The coating of the second covering material is formed by spraying,
The second covering material includes a granular material (2a) having a particle diameter of 0.05 to 5 mm, and a resin component (2b), and the solid content weight ratio thereof is 100 parts by weight of the granular material (2a). On the other hand, it is 1 to 50 parts by weight of the resin component (2b), and includes a colored granular material as the granular material (2a).

  In the film forming method of the present invention, the process of forming the specific first coating material and the process of forming the specific second coating material are performed in that order on the base material, thereby reducing the amount of the coating material used. Finished with natural stone-like texture and profound feeling.

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

The method for forming a coating of the present invention comprises performing a step of forming a coating of a specific first coating material on a substrate and a step of forming a coating of a specific second coating material in that order.
<Base material>
The base material constitutes a surface of a building, a civil engineering structure, or the like. Examples of such a substrate include concrete, mortar, siding board, extruded board, gypsum board, pearlite board, brick, and tile. These substrates may be those having a film already formed on the surface thereof.

<First covering material>
The first coating material of the present invention comprises a transparent granular material (1a) having a particle diameter of 0.05 to 5 mm (hereinafter also simply referred to as “transparent granular material (1a)”), a resin component (1b), and coloring. The pigment (1c) is contained at a specific weight ratio. After a specific amount of the first covering material is applied to form a film, the second covering material is formed to give a natural stone-like texture, a heavy feeling, etc. The amount used can be reduced. As a result, the total amount of coating material can be reduced.

In the present invention, the transparent powder (1a) having a light transmittance of 3% or more (preferably 3% or more and 50% or less, more preferably 10% or more and 30% or less) can be used. In addition, the light transmittance said here is the value of the total light transmittance by a turbidimeter. In this measurement, a sample of transparent aggregate is filled into a cell made of transparent glass having an inner thickness of 5 mm, and then gradually filled with water, and then the bubbles in the cell are removed by vibration.

Specific examples of such transparent granular materials include, for example, resin beads, silica sand, feldspar, silica stone, cryolite, and glass beads, and one or more of these can be used. In the present invention, it is particularly preferable to use cryogenic stone.

Various resin components can be used as the resin component (1b) of the present invention. Usable resins include, for example, vinyl acetate resin, vinyl chloride resin, epoxy resin, acrylic resin, urethane resin, acrylic silicon resin, fluororesin, etc., or a composite system thereof. More than seeds can be used. Examples of such synthetic resins include water-soluble resins, water-dispersible resins, NAD type resins, solvent-soluble resins, solventless resin types, and the like. Can be used. In the present invention, a one-component type of a water-soluble resin and / or a water-dispersible resin is particularly preferable.

The glass transition temperature of the resin component (1b) is preferably 10 ° C. or lower (more preferably −50 to 5 ° C.). In this case, the followability to the ground and the crack resistance can be improved, and the applicability of the second coating material can be further improved. The glass transition temperature is a value determined by the FOX equation.

As the color pigment (1c) of the present invention, a known color pigment can be used. Examples of color pigments that can be used include titanium oxide, zinc oxide, carbon black, black iron oxide, red bean, perylene red, quinacridone red, yellow iron oxide, benzimidazolone yellow, phthalocyanine green, ultramarine blue, bitumen, phthalocyanine blue, A quinacridone violet etc. are mentioned, These 1 type (s) or 2 or more types can be used. By adjusting the blending of the color pigment (1c) as appropriate and matching the color tone of the second coating material, the finish can be further enhanced.

  The 1st coating material of this invention contains the said transparent granular material (1a), the said resin component (1b), and the said color pigment (1c), and these solid content weight ratios are transparent granular materials (1a). 1 to 50 parts by weight (preferably 3 to 30 parts by weight) of resin component (1b) and 0.1 to 20 parts by weight (preferably 0.3 to 15 parts by weight) of color pigment (1c) with respect to 100 parts by weight Preferably 0.5 to 10 parts by weight. Thus, by including each component in a specific solid content weight ratio, it is possible to have appropriate transparency while concealing the base. Furthermore, irregularities can be formed on the formed film. Thereby, even if there is little usage-amount of a 2nd coating | covering material, the finish excellent in a texture, a profound feeling, etc. can be obtained.

  On the other hand, when the content ratio of the resin component (1b) is smaller than the above range, the transparent powder (1a) and the color pigment (1c) may not be sufficiently fixed and may be detached, and the above range. If it is larger than the range, the unevenness of the film may be insufficient. Further, when the content ratio of the color pigment (1c) is smaller than the above range, the concealing property of the base is inferior, and when it is larger than the above range, the transparency is inferior, and the effect of the present invention is hardly obtained.

  The first coating material of the present invention preferably contains extender pigment (1d) in addition to the above components. Examples of the extender pigment (1d) include heavy calcium carbonate, kaolin, clay, diatomaceous earth, talc, precipitated barium sulfate, silica powder, and the like, and one or more of these can be used. The particle diameter of the extender pigment (1d) is preferably 1 μm or more and less than 50 μm. The extender pigment (1d) is preferably contained in an amount of 1 to 100 parts by weight with respect to 100 parts by weight of the transparent granular material (1a). In such a case, a film can be formed stably.

  Furthermore, it is preferable that a 1st coating | covering material contains an elastic granular material (1e). Examples of the elastic powder (1e) include rubber powder and resin foam. By including an elastic granular material (1e), the applicability | paintability at the time of applying a 2nd coating | covering material can be improved further. As the elastic granular material (1e), those having a particle diameter of 0.05 to 5 mm and a light transmittance of less than 3% are preferable.

  The first coating material is, for example, a thickener, a wetting agent, an antifreezing agent, an antiseptic agent, an antifungal agent, an anti-algae agent, an antibacterial agent, a dispersant, and an antifoaming agent within a range that does not significantly impair the effects of the present invention. , UV absorbers, antioxidants, catalysts and the like may be included. The first covering material can be produced by uniformly mixing the above-described components by a conventional method.

<Second covering material>
The second coating material of the present invention includes a powder (2a) having a particle diameter of 0.05 mm or more and 5 mm or less (hereinafter also simply referred to as “powder (2a)”) and a resin component (2b). A colored granular material is included as the granular material (2a). This second covering material imparts a natural stone-like texture, design properties, and the like.

Examples of the granular material (2a) of the present invention include natural stone pulverized material, ceramic powder, ceramic powder, rubber particles, metal particles, resin beads, quartz sand, feldspar, quartzite, chlorite, and glass beads. 1 type (s) or 2 or more types can be used. In this invention, a colored granular material is included as a granular material (2a). Examples of the colored granular material include colored ones among the above granular materials (2a), and those whose surface is color-coated. Thereby, a natural stone-like texture, a design property, etc. can be provided.

The second covering material is preferably used in combination with colored powder particles so as to have the same color tone as the first covering material. Specifically, it is preferable to prepare such that the color difference ΔE between the first coating material and the second coating material is 20 or less. Thereby, the effect of the present invention can be further enhanced by the combination of the first covering material and the second covering material.

As the resin component (2b) of the present invention, various resin components can be used, and one or more selected from the same as the resin component (1b) described above can be used. The glass transition temperature of the resin component (2b) is preferably −20 ° C. or higher (more preferably −10 to 30 ° C.). In this case, it is suitable in terms of crack resistance, contamination resistance and the like.

  The 2nd coating material of this invention contains the said granular material (2a) and the said resin component (2b), and these solid content weight ratios are resin components (100 parts by weight of the granular material (2a)). 2b) 1 to 50 parts by weight (preferably 3 to 30 parts by weight).

  The second coating material is, for example, a colorant, a thickener, a wetting agent, an antifreezing agent, an antiseptic agent, an antifungal agent, an anti-algae agent, an antibacterial agent, and a dispersant within a range that does not significantly impair the effects of the present invention. Further, it may contain an antifoaming agent, an ultraviolet absorber, an antioxidant, a catalyst and the like. The second covering material can be produced by uniformly mixing the above-described components by a conventional method.

<Film formation method>
The film forming method of the present invention comprises performing a step (1) of forming a film of the first covering material on a substrate and a step (2) of forming a film of the second covering material in that order.

In the present invention, before the step (1), the substrate can be subjected to treatments such as washing and base preparation. For the cleaning treatment, a method of washing with water after applying various cleaning agents to the substrate as necessary may be adopted. In addition, the base preparation can be performed by some surface treatment (sealer, primer, filler, putty, surfacer, etc.).

In the said process (1), the method of forming the film of a 1st coating | covering material on a base material is not specifically limited, For example, it can carry out using well-known applicators, such as a brush, a spray, a roller. In the present invention, it is particularly preferable to form by spraying using a spray or the like. The amount of the first coating material used (in terms of solid content) is 0.3 to 3 kg / m ² (preferably 0.4 to 2.5 kg / m ² , more preferably 0.5 to ² kg / m ² ). . In this case, it is possible to have appropriate transparency while concealing the base. Furthermore, irregularities can be formed on the formed film. Thereby, even if there is little usage-amount of a 2nd coating | covering material, the finish excellent in a texture, a profound feeling, etc. can be obtained. On the other hand, when the usage-amount of a 1st coating material is less than the said range, there exists a possibility that it may be inferior to the concealment property of a foundation | substrate, and when it exceeds the said range, the improvement of the effect of this invention is difficult to be recognized. The first coating material is preferably applied at room temperature (0 to 40 ° C.).

In the present invention, after the step (1), the step (2) may be performed either before or after drying the first coating material. The first covering material is preferably dried at room temperature.

In the above step (2), the method for forming the second coating material film on the coating film formed by the first coating material is not particularly limited. For example, a known applicator such as a brush, a spray, or a roller is used. Can be done using. In the present invention, it is particularly preferable to form by spraying using a spray or the like. In this invention, the coating property of the 2nd coating | covering material can be improved because the film formed with the said 1st coating | covering material has an unevenness | corrugation. In particular, when the second covering material is sprayed, the effect is remarkable, and scattering of the granular material (2a) can also be suppressed when the second covering material is sprayed. The amount used (in terms of solid content) when applying the second coating material is preferably 0.3 to 3 kg / m ² (more preferably 0.4 to 2.5 kg / m ² , and still more preferably 0.5). ˜2 kg / m ² ). In such a case, natural stone-like texture, profound feeling, designability, etc. can be imparted. Note that the application and drying of the second covering material are preferably performed at room temperature.

  As the film forming method of the present invention, the peelable joint material is removed after the step of installing a peelable joint material (masking material) on the substrate, the step (1), and the step (2). The steps can be performed in this order. Thereby, a good natural stone-like texture, designability, etc. can be imparted even at the joint. In this invention, a transparent coating | covering material etc. can also be applied after the said process (2).

Examples are given below to clarify the features of the present invention.
[First coating material: Coating materials 1-1 to 1-6]
The raw materials shown in Table 1 were mixed by a conventional method to prepare coating materials 1-1 to 1-6. In addition, the following were used as a raw material.
・ Transparent powder (1a): Cold stone (particle diameter 0.1-0.5 mm, light transmittance 16%)
Resin component (1b): acrylic resin emulsion (solid content 50% by weight, glass transition temperature -30 ° C.)
Colored pigment (1c): mixed dispersion of titanium oxide, yellow iron oxide, bengara and carbon black (solid content 50% by weight)
-Extender pigment (1d): heavy calcium carbonate (average particle size 2 μm)
・ Additives: thickeners, antifoaming agents, film-forming aids, etc.

[Second coating material: Coating material 2-1]
Powder material (2a) 100 parts by weight, resin component (2b) 20 parts by weight, and additives were mixed by a conventional method to prepare a covering material 2-1. In addition, the following were used as a raw material.
・ Powder (2a): colored silica sand (reddish brown, particle size 0.1 to 0.5 mm)
Resin component (2b): acrylic resin emulsion (solid content 50% by weight, glass transition temperature 0 ° C.)

Example 1
A coating material 1-1 is sprayed onto a base material (slate plate) [amount used (converted to solid content) 1.0 kg / m ² ] to form a first coating, which is then dried at room temperature for 2 hours, and then coated. The material 2-1 was sprayed [used amount (in terms of solid content) 1.2 kg / m ² ] to form the second coating, and dried at room temperature for 24 hours. The result of evaluating the appearance of the formed film was “◎”. The evaluation criteria are 4 grades (excellent ◎>○> △) with “◎” for natural stone-like texture and excellent texture, and “X” for natural stone-like texture and insufficient texture. > × poor).

(Example 2)
A coating film was formed in the same manner as in Example 1 except that the coating material 1-2 was used instead of the coating material 1-1 in Example 1, and the same evaluation was performed. The result was “◎”.

(Example 3)
A coating film was formed in the same manner as in Example 1 except that the coating material 1-3 was used instead of the coating material 1-1 in Example 1, and the same evaluation was performed. The result was “◎”.

(Example 4)
A coating was formed in the same manner as in Example 1 except that the covering material 1-4 was used in place of the covering material 1-1 in Example 1, and the same evaluation was performed. As a result, it was “◯”.

(Comparative Example 1)
A coating was formed in the same manner as in Example 1 except that the covering material 1-5 was used instead of the covering material 1-1 in Example 1, and the same evaluation was performed. The result was “Δ”.

(Comparative Example 2)
A coating film was formed in the same manner as in Example 1 except that the covering material 1-6 was used instead of the covering material 1-1 in Example 1, and the same evaluation was performed. The result was “x”.

Claims (1)

A method of forming a film of a first covering material on a base material, a step of forming a film of a second covering material, and a film forming method for performing in that order,
The coating of the first covering material is formed by spraying,
The first covering material includes a transparent granular material (1a) having a particle diameter of 0.05 to 5 mm, a resin component (1b), and a coloring pigment (1c), and the solid content weight ratio thereof is the transparent granular material. 1 to 50 parts by weight of the resin component (1b) and 0.1 to 20 parts by weight of the color pigment (1c) with respect to 100 parts by weight of the body (1a),
The amount of the first coating material used (in terms of solid content) is 0.4 to 3 kg / m ² .
The coating of the second covering material is formed by spraying,
The second covering material includes a granular material (2a) having a particle diameter of 0.05 to 5 mm, and a resin component (2b), and the solid content weight ratio thereof is 100 parts by weight of the granular material (2a). On the other hand, it is 1 to 50 parts by weight of the resin component (2b), and includes a colored granular material as the granular material (2a).