JP6719407B2 - Film forming method - Google Patents

Description

The present invention relates to a method for forming a film on inner and outer wall surfaces of a building or a civil engineering structure.

2. Description of the Related Art Conventionally, there is known a decorative finishing method for imparting a natural stone-like appearance, a high-class feeling, a solid feeling to a building or a civil engineering structure. As such a construction method, for example, in Patent Document 1, after applying a first spraying material containing a synthetic resin emulsion and an aggregate, a second spraying material containing a mica flakes is partially formed on the surface thereof. A coating forming method for coating is described.

Japanese Patent Laid-Open No. 11-319698

As described in Patent Document 1, the decorative finishing method is usually applied by spraying, but in recent years, scattering of aggregates or the like may be a problem depending on the location environment of the building. .. Further, in order to give an accent design, it is necessary to apply the design material in a separate process, which may complicate the process. Under such circumstances, there is a demand for a simple method capable of finishing with a natural stone tone having an accent design.

The present invention has been made in view of such problems, and an object thereof is to obtain a film forming method using a roller and capable of natural stone finish having an accent design with one covering material. ..

As a result of intensive studies to solve the above problems, the present inventors applied a specific coating material containing a water-based resin, granular aggregate and specific scale-like colored particles using a specific roller. As a result, it was conceived that a natural stone-finished coating having an accent design can be formed, and the present invention has been completed.

That is, the present invention has the following features.
1. A coating forming method for forming a pattern coating by coating a coating material (I) on a substrate using a roller,
The roller is a porous roller whose surface has pores having a size of 3 mm or more occupying 50% or more,
The coating material (I) is an aqueous resin (A), a granular aggregate (B), and a major axis having a major axis of 1 mm or more, and a ratio of minor axis to major axis (minor axis/major axis) of 0.5 to 1. Colored particles (C) as an essential component,
100 to 2000 parts by weight of the granular aggregate (B) and 0.5 to 100 parts by weight of the scale-like colored particles (C) per 100 parts by weight of the solid content of the aqueous resin (A),
The scale-like colored particles (C) have a particle size distribution in which the ratio of particles having a major axis of 2.5 mm or more is 15% or more and the ratio of particles having a major axis of more than 3.5 mm is 15% or less. Method.

According to the present invention, an aqueous resin, a specific covering material containing a granular aggregate and specific scaly colored particles, by applying using a specific roller, excellent natural stone tone finish with an accent design A coating can be formed.

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

The present invention relates to a film forming method of forming a pattern film by applying a coating material (I) on a substrate using a roller. As the roller, a porous roller having 50% or more of holes having a size of 3 mm or more on its surface is used. By using such a roller and applying the specific coating material (I) containing the water-based resin, the granular aggregate and the specific colored flake-like particles, it is possible to easily achieve an excellent natural stone tone finish in which the accent design is visually recognized. Can be done.

In the present invention, the pore size of the porous roller and the particle size (particularly the major axis) of the colored scale-like particles are set to a certain combination, whereby the transferability of the colored scale-like particles at the time of film formation becomes good, and the accent design It is possible to form a film having excellent visibility.

<Substrate>
The base material constitutes the surface of a building, a civil engineering structure, or the like. Examples of such a base material include concrete, mortar, siding board, extruded board, gypsum board, perlite board, plywood, brick, plastic board, metal board, glass, and porcelain tile. These base materials may have a coating film already formed on their surface, or have a wallpaper attached thereto.

<Porous roller>
The porous roller used in the present invention is one in which a porous layer is provided on the outer surface of a tubular core material, and the tubular core material becomes a hollow so that a handle equipped with a shaft can be mounted. The handle shaft can be attached to the cavity for use.
The cylindrical core material is not particularly limited, and for example, a core material made of plastic, wood, paper, metal or the like can be used, and in order to improve the adhesion between the handle shaft and the core material. A reinforcing material made of plastic, rubber, glass, metal, fiber or the like may be used between the handle shaft and the core material.

The surface of the porous roller used in the present invention (the surface of the outer periphery of the porous layer) has 50% or more holes having a size of 3 mm or more, and preferably 50% or more holes having a size of 3 mm to 8 mm. Is 60% or more of the holes of 3 mm or more and 8 mm or less, and more preferably 70% or more of the holes of 3 mm or more and 8 mm or less). In the present invention, the size of the hole may be calculated by the maximum distance×2 from the center of gravity of each hole. Further, the ratio of pores having a size of 3 mm or more is calculated by (number of pores having a size of 3 mm or more appearing on the surface of the porous layer)/(total number of pores appearing on the surface of the porous layer)×100(%) Is the value to be set.

Examples of such a porous layer include a porous layer having communicating pores, a porous layer having independent pores, and the like. In the present invention, a porous layer having communicating pores is preferable. The material thereof is not particularly limited, but examples thereof include acrylic resin, urethane resin, ester resin, ethylene resin, and the like, and those obtained by making these resins porous in a sponge form are preferable.

The thickness of the porous layer is preferably 3 mm or more and 50 mm or less, more preferably 5 mm or more and 30 mm or less. With such a thickness, the coating efficiency of the coating material is good and the workability is superior. The width (length) of the porous roller is not particularly limited, but is preferably about 80 mm or more and 250 mm or less, and the diameter (cylindrical diameter) of the porous roller (including the porous layer) is preferably about 30 mm or more and 100 mm or less. is there.

<Coating material (I)>
The coating material (I) used in the present invention contains the aqueous resin (A), the granular aggregate (B), and the scaly colored particles (C) as essential components.

As the aqueous resin (A) (hereinafter referred to as “component (A)”), one or more selected from water-soluble resins and water-dispersible resins are suitable. Examples of the type of resin include vinyl acetate resin, polyester resin, alkyd resin, vinyl chloride resin, epoxy resin, acrylic resin, urethane resin, acrylic silicone resin, fluororesin, and the like, or a composite system thereof. .. These can be used alone or in combination of two or more. Moreover, these (A) components may have a crosslinking reactivity. When the component (A) having crosslinking reactivity is used, the water resistance, weather resistance, chemical resistance, etc. of the coating can be improved.

As the granular aggregate (B) (hereinafter referred to as “(B) component”), at least one selected from natural aggregates such as natural stones and crushed natural stones, and artificial aggregates such as colored aggregates is preferable. Can be used for Specifically, for example, marble, granite, serpentine, granite, fluorite, cold water stone, feldspar, silica stone, silica sand, and crushed products thereof, ceramic crushed products, ceramic crushed products, glass crushed products, glass beads, resins Examples include pulverized products, resin beads, metal particles, and those whose surface is colored and coated. By using one kind or a combination of two or more kinds thereof, various natural stone tone colors can be expressed.

The average particle diameter of the component (B) is preferably 0.01 to 1 mm (more preferably 0.02 to 0.8 mm, further preferably 0.03 to 0.6 mm). The average particle diameter is a value obtained by sieving using a metal mesh sieve defined in JIS Z8801-1:2000 and calculating the average value of the weight distribution. Such component (B) is recognized as granular and is different from scale-like particles described later.

The component (B) is mixed at a ratio of 100 to 2000 parts by weight (preferably 150 to 1500 parts by weight, more preferably 200 to 1000 parts by weight) with respect to 100 parts by weight of the solid content of the component (A). If the component (B) is mixed in such a ratio, a thick film can be easily formed, and the solid feeling of the formed film can be increased.

In the present invention, the granular aggregate (B-1) having transparency (hereinafter, referred to as “(B-1) component”) is preferably contained as the (B) component. By using such a component (B-1), the accented design is easily visible in the formed film. As the component (B-1), one having a light transmittance of 3% or more (more preferably 3 to 50%, further preferably 10 to 30%) is preferable. When the light transmittance is 50% or less, it is advantageous to secure the concealing property of the entire coating. The light transmittance is the value of total light transmittance measured by a turbidimeter. In this measurement, a sample of the component (B-1) is filled in a transparent glass cell having an inner thickness of 5 mm, then gradually filled with water, and then bubbles in the cell are removed by vibration.

Examples of the component (B-1) include feldspar, silica sand, silica stone, cold water stone, glass beads, and the like. Among these, cold water stone is particularly preferable in the present invention. The average particle diameter of the component (B-1) may be any as long as it satisfies the above range, but is preferably 0.01 to 1 mm (more preferably 0.02 to 0.8 mm, further preferably 0. 03-0.6 mm).

The content of the component (B-1) is preferably 20% by weight or more (preferably 30% by weight or more, more preferably 50% by weight or more) based on the total amount of the component (B). The upper limit is preferably 90% by weight or less (preferably 80% by weight or less) based on the total amount of the component (B). When the component (B-1) is contained in a high ratio in this way, the visibility of the accent design can be enhanced and the concealing property of the entire coating film can be secured.

The scale-like colored particles (C) (hereinafter referred to as “(C) component”) have a major axis of 1 mm or more, and a ratio of minor axis to major axis (minor axis/major axis) of 0.5 to 1, which is an accent design. It is what imparts sex. When the size of the component (C) satisfies the above range, its shape is easily visible, which is suitable as an accent design. On the other hand, when the thickness is out of the above range, the shape is needle-like to thin rod-shaped, so that the shape is buried in the coating and is hardly visible. The major axis and the minor axis of the component (C) are values measured by allowing the component (C) to stand still on a horizontal surface and observing with a microscope from above.

The thickness of the component (C) is preferably 50 to 500 μm (more preferably 60 to 450 μm). In such a case, the component (C) is likely to be stably aligned and transferred to the surface of the coating, and the effect of the present invention can be enhanced. In the present invention, the term “scaly” means that the ratio of major axis to thickness satisfies (major axis/thickness)>2. The thickness of the component (C) is a value measured by a micrometer.

In the present invention, at least one color of the component (C) has a ratio of particles having a major axis of 2.5 mm or more of 15% or more (preferably 20% or more, more preferably 25% or more) and a major axis of 3 in the particle size distribution. The ratio of particles having a size of more than 0.5 mm is 15% or less (preferably 10% or less, more preferably 5% or less). When the component (C) satisfies the above-mentioned particle size distribution, the transferability of the component (C) is enhanced, and the film with good visibility of the accent design and excellent aesthetics can be formed. On the other hand, in the component (C), when the ratio of particles having a major axis of 2.5 mm or more is less than 15%, the accent design is hard to be visually recognized, and when the ratio of particles having a major axis of more than 3.5 mm exceeds 15%, the coating film is formed. Poor transferability and easy unevenness.

The particle size distribution of the component (C) is [the number of (C) of a predetermined color of major axis 2.5 mm or more (or major axis more than 3.5 mm), minor axis/major axis=0.5 to 1]/[major axis 1 mm or more]. , (Minor axis/major axis=total number of (C) of a predetermined color of 0.5 to 1]×100%. The total number of (C) of the predetermined color may be randomly extracted at about 50.

Examples of such component (C) include those obtained by subjecting scale-like base particles to a coloring treatment. Specific examples of the base particles include, for example, mica, sericite, clay, talc, tabular kaolin, barium sulfate flake, glass flake, alumina flake, shell pieces, inorganic pieces such as metal pieces, or rubber pieces, plastic pieces, Examples include wood chips. The coloring treatment is not particularly limited, but a method of coating the base particle surface with a coloring agent containing a pigment is preferable. The component (C) can be used alone or in combination of two or more kinds (one color or two or more colors) and can express various colors.

The component (C) is mixed in a ratio of 0.5 to 100 parts by weight (preferably 1 to 80 parts by weight) with respect to 100 parts by weight of the solid content of the component (A). If the component (C) is mixed in such a ratio, the accent design is easily visible, and a natural stone-finished coating having excellent aesthetics can be formed.

Further, in the present invention, it is preferable to include uncolored scale-like particles (D) (hereinafter referred to as “(D) component”). Since the component (D) is not subjected to a coloring treatment with a coloring agent, it is possible to impart a natural design property to the formed film. As such a component (D), for example, scaly particles or the like which are the base of the above component (C) can be used. Above all, in the case of imparting a natural texture, it is preferable to include uncolored scale-like particles such as shell pieces such as scallop pieces, coral pieces, and wood pieces.
Further, in the case of imparting a natural glittering feeling, calcined clay mineral particles obtained by calcining clay minerals such as mica, sericite, clay, talc and plate kaolin are preferable, and calcined mica is particularly preferable. Clay mineral particles such as mica have a property that they can be exfoliated into a smaller piece than ordinary mica because the hydroxyl group (—OH) (crystal water) is removed from the structure by firing. In addition, since the surface state is changed by firing and a glittering feeling is manifested by itself, a natural glittering feeling can be imparted to the formed film. The firing temperature may be a temperature at which the crystalline water in the clay mineral particles can be dehydrated, and is preferably 500 to 2000°C.

The size of the component (D) may be in the range that does not impair the design of the component (C), but is preferably 0.5 mm or more in the major axis and the ratio of the minor axis to the major axis (minor axis/major axis). It is 0.5 to 1. In the particle size distribution, the ratio of particles having a major axis of 1 mm or more is preferably 15% or more (more preferably 20% or more, further preferably 25% or more), and the ratio of particles having a major axis of more than 3.5 mm is preferably 15% or less. (More preferably 10% or less, still more preferably 5% or less).
When the size of the component (D) satisfies the above range, natural designability and the like can be imparted while utilizing the designability of the component (C). The thickness of the component (D) may be in the range that satisfies the scaly condition of the present invention.

The component (D) is mixed in a ratio of preferably 0.5 to 100 parts by weight (more preferably 1 to 80 parts by weight) with respect to 100 parts by weight of the solid content of the component (A). When the component (D) is mixed in such a ratio, it is possible to impart a natural design property to the formed film.

In the present invention, the large particles having an average particle diameter other than the components (B), (C), and (D) above 1 mm to 10 mm (preferably 1.2 to 5 mm) are further used in the present invention. May be included unless it significantly inhibits.

The coating material (I) of the present invention can be produced by uniformly mixing the above components by a known method, but if necessary, other components that can be usually used in the coating material may be mixed. it can. Examples of such components include color pigments, extender pigments, fibers, film-forming aids, thickeners, leveling agents, plasticizers, antifreezing agents, pH adjusting agents, preservatives, mildew-proofing agents, and anti-algal agents. , Antibacterial agents, dispersants, defoamers, ultraviolet absorbers, antioxidants, water and the like.

The coating amount of the coating material (I) of the present invention is not particularly limited, but is preferably 0.5 to 5 kg/m ² , and more preferably 1 to 3 kg/m ² . At the time of application, the coating material of the present invention can be diluted with water. The dilution ratio is preferably 0 to 10% by weight.

After forming a film with the coating material of the present invention, a clear paint, a water repellent, or the like can be applied, if necessary. Among these, examples of the clear paint include acrylic resin-based paint, urethane resin-based paint, epoxy resin-based paint, acrylic silicone resin-based paint, and fluororesin-based paint. In such a clear paint, the degree of luster can be adjusted by blending a matting agent or the like. Further, coloring can be applied as long as the effect of the present invention is not impaired. As the water repellent, those containing an alkoxysilane compound or a silicone resin as a main component can be used. As a method of applying such a clear coating material or a water repellent agent, a known method can be adopted, for example, spray coating, roller coating, brush coating and the like can be adopted.

Examples will be shown below to further clarify the characteristics of the present invention.

(Coating materials I-1 to I-13)
Based on the formulations shown in Table 1, the respective raw materials were mixed by a conventional method, and water was mixed so that the viscosity (B-type viscometer, 2 rpm) was 80 Pa·s to produce coating materials I-1 to I-13. ..

The following components were used as each component.
・(A) Acrylic resin emulsion (solid content 50% by weight)
-(B) Granular aggregate (mixture of white silica sand and yellow brown silica sand, average particle diameter 120 μm, light transmittance 1% or less)
・(B-1) Transparent granular aggregate (cold stone, average particle size 200 μm, light transmittance 16%)
・Additives (thickeners, defoamers, etc.)

-(C1) to (C6) Scale-like colored particles

-(D1) to (D3) uncolored scale-like particles

(Examples 1 to 13, Comparative Examples 1 to 2)
On the base material (slate plate) coated with the undercoat material, the coating material was applied at a coating amount of 2 kg/m ² using the porous roller and the coating material shown in Table 4, and dried at 23° C. for 24 hours. Then, it was cured to form a pattern film.
Each of the used porous rollers 1 to 3 has a diameter (cylindrical diameter) of 70 mm, a roller width of 200 mm, a paper core material, and a sponge-like porous layer (communicating hole) of 15 mm in thickness porous layer. The surface of the porous layer has pores with a size of 3 mm or more and 8 mm or less,
82% for roller 1,
70% for roller 2,
88% for roller 3,
Occupy.

<Evaluation>
The following evaluations were carried out and the results are shown in Table 4.
-Painting workability: Excellent coating workability was evaluated as "◎" and inferior workability was evaluated as "x", and was evaluated in four grades of ◎>○>△>×.
Transferability The transferability of the scale-like particles at the time of forming the film was evaluated as “⊚”, and the inferior transferability was evaluated as “x”, and the evaluation was made in four levels of ⊚>○>Δ>x.
・Aesthetic accents Designs with excellent visibility were rated as "⊚" and inferior ones as "×", and were evaluated in four levels of ◎>○>△>x.

In Examples 1 to 13, natural stone-like coatings having excellent coating workability, transferability of the scale-like colored particles, and excellent aesthetic appearance with an accent design were formed. Further, in Example 11, a natural lustrous film was formed, and in Examples 12 to 13, a natural stone-like coating having a natural texture was formed. On the other hand, in Comparative Example 1, the accent design was insufficient. Comparative Example 2 was inferior in coating workability and transferability of the scale-like colored particles, and a coating film having unevenness was formed.

Claims (1)

A coating forming method for forming a pattern coating by coating a coating material (I) on a substrate using a roller,
The roller is a porous roller whose surface has pores having a size of 3 mm or more occupying 50% or more,
The coating material (I) is an aqueous resin (A), a granular aggregate (B), and a major axis having a major axis of 1 mm or more, and a ratio of minor axis to major axis (minor axis/major axis) of 0.5 to 1. Colored particles (C) as an essential component,
100 to 2000 parts by weight of the granular aggregate (B) and 0.5 to 100 parts by weight of the scale-like colored particles (C) per 100 parts by weight of the solid content of the aqueous resin (A),
The scale-like colored particles (C) have a particle size distribution in which the ratio of particles having a major axis of 2.5 mm or more is 15% or more and the ratio of particles having a major axis of more than 3.5 mm is 15% or less. Method.