JP2021137812A - Film formation method - Google Patents

Abstract

To obtain efficiently an uneven pattern having random aesthetic property.SOLUTION: Following steps are performed successively to a substrate: (1) a step of applying a covering material containing an aqueous resin and granules, in which a content rate of the granules is 30-90 wt.%, a heating residue is 50-95 wt.%, and a flow value is 100-180 mm, (2) a step of adding unevenness having a depth of 1-10 mm to a coating surface by pressing a flat plate onto the coating surface and pulling up the flat plate from the coating surface, while the coating surface of the covering material is undried.SELECTED DRAWING: None

Description

The present invention relates to a novel film forming method.

Conventionally, uneven patterns such as natural stones have been formed on the inner and outer walls of buildings and the surfaces of civil engineering structures for the purpose of improving aesthetics. As a means for obtaining such an uneven pattern, a method of utilizing various covering materials is known.

For example, Japanese Patent Application Laid-Open No. 5-68937 (Patent Document 1) describes a method of imparting an uneven pattern using a net body and a spraying material. Specifically, the method of the publication is to install a grid-like net body on the wall surface using an adhesive, and then paint a spray material to make a void in the net body a recess.

Japanese Unexamined Patent Publication No. 5-68937

However, in the method described in the above-mentioned publication, since the uneven pattern is formed according to the lattice shape of the net body, the interval between the unevenness becomes regular.

Further, in the method described in the above publication, an uneven pattern is formed by using three kinds of materials, an adhesive material, a net body, and a spraying material. Therefore, the work of forming the uneven pattern becomes complicated, which may lead to a long construction period.

The present invention has been made in view of these points, and an object of the present invention is to efficiently obtain an uneven pattern having a random aesthetic appearance.

In order to solve such a problem, the present inventors, as a result of diligent studies, sequentially perform a step of applying a specific coating material to a base material and a step of imparting unevenness to the coated surface by a specific method. And came to complete the present invention.

That is, the present invention has the following features.
1. 1. It is a method of forming a film having an uneven pattern, and is a method for forming a film having an uneven pattern.
(1) A coating material containing an aqueous resin and powder or granular material having a content of the powder or granular material of 30 to 90% by weight, a heating residue of 50 to 95% by weight, and a flow value of 100 to 180 mm is applied. Process,
(2) While the coated surface of the covering material is not dried, a flat plate is pressed against the coated surface and the flat plate is pulled up from the coated surface to impart irregularities having a depth of 1 to 10 mm to the coated surface. Process,
A method for forming a film, which comprises performing the above steps in order.
2. Following the above (1) step and the above (2) step,
(3) The step of treating the unevenness of the coated surface,
The feature is that 1. The film forming method according to the above.
3. 3. The step (3) is a step of tapping the coated surface with a wet instrument while the coated surface is not dried. The film forming method according to the above.
4. 3. The instrument used in the above step (3) is a spongy material or a fibrous material. The film forming method according to the above.
5. 3. The instrument used in the above step (3) is one or more selected from dandelion, sponge, and felt. The film forming method according to the above.
6. The powder or granular material contains an extender pigment, a color pigment, and an aggregate, and the weight ratio of the extender pigment, the color pigment, and the aggregate is 100: (1 to 100) :( 10 to 1000). 1. From 5. The film forming method according to any one of.
7. The material of the flat plate is one or more selected from metal, resin, and wood. From 6. The film forming method according to any one of.
8. The thickness of the flat plate is 0.1 to 1 mm. From 7. The film forming method according to any one of.
9. The flat plate has a pointed tip portion, and the tip portion is flexible. From 8. The film forming method according to any one of.

According to the present invention, it is possible to efficiently obtain an uneven pattern having a random aesthetic appearance. In the present invention, it is also possible to form a deep and large uneven pattern.

FIG. 1 is a bottom view showing an example of a flat plate. FIG. 2 is a cross-sectional view showing an example of an instrument provided with a flat plate.

1: Flat plate 10: Tip portion 11: Tip portion apex 12: Bottom portion 13: Bottom both ends 14: Central portion 15: Bottom surface 16: Top surface 2: Handle 3: Support material L: Flat plate length W: Flat plate width

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

The present invention can be mainly applied to the inner and outer wall surfaces of buildings, ceilings, floors, etc., or the surfaces of civil engineering structures. Examples of the base material constituting such a part include concrete, mortar, siding board, extruded board, gypsum board, pearlite board, plywood, plastic board, metal board, woodwork board, glass, brick, ceramic tile and the like. Various base materials can be mentioned. These base materials may be those that have been subjected to some surface treatment (filler treatment, surfacer treatment, sealer treatment, etc.), those that have been pre-colored with a colored paint, etc., those that have already formed a film, or those to which wallpaper is attached. It may be attached.

In the present invention, the base material contains an aqueous resin and powder or granular material as step (1), the content of the powder or granular material is 30 to 90% by weight, the heating residue is 50 to 95% by weight, and the flow. A coating material having a value of 100 to 180 mm is applied. A covering material having such a physical property value is suitable for forming an uneven pattern in the present invention.

The water-based resin acts as a binder. Examples of the water-based resin include water-dispersible resins and / or water-soluble resins. Examples of these resin types include acrylic resin, urethane resin, epoxy resin, vinyl chloride resin, vinyl acetate resin, acrylic silicon resin, fluororesin, polyvinyl alcohol, cellulose derivative, and the like, or a composite thereof. Such a resin component may have a property of causing a cross-linking reaction after the film is formed.

Examples of the powder or granular material include extender pigments, coloring pigments, aggregates and the like. These can be used alone or in combination of two or more.

Examples of extender pigments include heavy calcium carbonate, calcium carbonate, light calcium carbonate, barium sulfate, clay, kaolin, pottery clay, China clay, talc, precipitated barium sulfate, barium carbonate, white carbon, diatomaceous soil, hollow beads and the like. Can be mentioned. The average particle size of these extender pigments is preferably less than 50 μm, more preferably 0.5 μm or more and 45 μm or less, and further preferably 1 μm or more and 40 μm or less. The average particle size of the extender pigment is a value measured by a laser diffraction type particle size distribution measuring device.

Examples of coloring pigments include titanium oxide, zinc oxide, carbon black, ferric oxide (bengala), yellow iron oxide, iron oxide, silicon oxide, ultramarine, cobalt green, magnesium oxide, zirconium oxide, yttrium oxide, and indium oxide. , Inorganic coloring pigments such as alumina, azo-based, naphthol-based, pyrazolone-based, anthraquinone-based, perylene-based, quinacridone-based, disazo-based, isoindolinone-based, benzoimidazole-based, phthalocyanine-based, quinophthalone-based organic coloring pigments, pearls. Pigments, aluminum pigments, fluorescent pigments and the like can be mentioned. The average particle size of these coloring pigments is preferably 10 μm or less, more preferably 0.01 μm or more and 1 μm or less, and further preferably 0.03 μm or more and 0.8 μm or less. The average particle size of the coloring pigment is a value measured by a laser diffraction type particle size distribution measuring device.

Examples of the aggregate include cold water stone, silica sand, gravel, glass beads, resin beads, metal grains, or crushed products such as rock, glass, ceramics, shells, sintered bodies, plastics, and rubber. These may be colored. The average particle size of these aggregates is preferably 0.05 mm or more and 5 mm or less, and more preferably 0.06 mm or more and 2 mm or less. The average particle size of the aggregate is a value obtained by sieving using a metal net sieve specified in JIS Z8801-1: 2000 and calculating the average value of the weight distribution thereof.

The embodiment containing the above-mentioned extender pigment, coloring pigment, and aggregate as the powder or granular material is preferable in the present invention. The weight ratio of each of these powders and granules (constituent pigment: coloring pigment: aggregate) is preferably 100: (1 to 100) :( 10 to 1000), more preferably 100: (5 to 80) :( 50 to ~). 800). When the ratio of each powder or granular material is within such a range, an uneven pattern having depth and smoothness is likely to be formed, which is more preferable. In addition, a coating material having the above flow value can be easily obtained.

The content of the powder or granular material in the coating material is usually 30 to 90% by weight, preferably 40 to 85% by weight. If the content of the powder or granular material does not satisfy the above range, it becomes difficult to form an uneven pattern by pulling up the flat plate. On the other hand, if the content of the powder or granular material is too lower than the above value, it becomes difficult to thicken the film, and it becomes difficult to obtain an uneven pattern having depth. If the content of the powder or granular material is too higher than the above value, problems may occur in the physical characteristics of the film such as adhesion.

In addition to the above components, the coating material includes, for example, a diluent, a film-forming aid, a hardening agent, a plasticizing agent, a preservative, a fungicide, an algae-proofing agent, an antibacterial agent, a thickener, a defoaming agent, and a leveling agent. Includes surfactants, dispersants, anti-settling agents, anti-dripping agents, wetting agents, catalysts, curing accelerators, defoamers, matting agents, antifreeze agents, UV absorbers, antioxidants, light stabilizers, etc. It may be a thing.

The heating residue of the covering material is usually 50 to 95% by weight, preferably 60 to 90% by weight. If the heating residue of the covering material does not satisfy the above range, it becomes difficult to form an uneven pattern by pulling up the flat plate. On the other hand, if the heating residue of the covering material is too lower than the above value, it becomes difficult to thicken the film, and it becomes difficult to obtain an uneven pattern having depth. If the heating residue of the covering material is too high than the above value, the workability at the time of coating may be hindered. The heating residue of the coating material is a value measured by the method of JIS K 5601-1-2, and the heating temperature is 105 ° C. and the heating time is 60 minutes.

The flow value of the covering material is usually 100 to 180 mm, preferably 110 to 160 mm, preferably 115 to 155 mm. If the flow value of the covering material does not satisfy the above range, it becomes difficult to form an uneven pattern by pulling up the flat plate. Further, if the flow value of the covering material is too lower than the above value, the workability at the time of coating may be hindered. If the flow value of the covering material is too higher than the above value, it becomes difficult to obtain an uneven pattern having depth. The flow value of the covering material is a value measured by JIS R5201 “11. Flow test”, and the measured temperature is 23 ° C. Such a flow value can be adjusted by, for example, the composition of the powder or granular material, the heating residue of the coating material, and the like.

In the step (1), the coating material is applied to the base material. The method of applying the coating material is not particularly limited, and for example, a method such as spray coating, roller coating, or trowel coating can be adopted. The amount of the coating material applied is preferably 0.2 to 8 kg / m ² (more preferably 0.5 to 6 kg / m ² ).

In the step (2), while the coated surface of the covering material is not dried, the flat plate is pressed against the coated surface and the flat plate is pulled up from the coated surface to impart unevenness to the coated surface. In the present invention, since the covering material having the above-mentioned characteristics is used, when the flat plate is pressed against the coated surface and the flat plate is pulled up, the covering material is pulled together with the flat plate and lifted. By repeating this operation while changing the location as appropriate, a random, deep, and large uneven pattern is formed. Examples of the type of the uneven pattern include a ripple shape, a mountain shape, a hill shape, and a hump shape. The depth of the uneven pattern is 1 to 10 mm, more preferably 2 to 8 mm. In the present invention, such an uneven pattern can be obtained more stably by using a flat plate having flexibility. The undried state in the present invention refers to a state before curing and drying.

Examples of the material of the flat plate include metal, resin, and wood, and among them, metal is preferable. Examples of the metal plate include an iron plate, a steel plate, an aluminum plate, a stainless plate, and the like. The thickness of the flat plate is preferably 0.1 to 1 mm, more preferably 0.2 to 0.8 mm.

As an instrument provided with such a flat plate, a trowel having a flat plate having a pointed tip portion and having a flexible tip portion is suitable. An example thereof is shown in FIGS. In the present invention, by using such a trowel, a concave-convex pattern coating can be formed with a relatively simple operation. Such an effect is that pressure is easily applied to the tip portion 10 of the flat plate 1 with a relatively small force during use, which causes the tip portion 10 of the flat plate 1 to bend, and the tip portion 10 is applied over a relatively large area. It is considered that the fact that it is easier to come into contact with the surface contributes.

FIG. 1 shows an example of the flat plate 1. The lower surface 15 of the flat plate 1 is a portion in contact with the coated surface (coated surface before drying) of the covering material.

FIG. 1 is a view of the flat plate 1 from the lower surface 15 side. The tip portion 10 of the flat plate 1 shown in FIG. 1 has a sharp shape. Examples of the shape of the tip portion 10 include an inverted V-shape and an inverted U-shape, and the inverted V-shape is preferable in the present invention. The angle (internal angle) of the tip apex 11 is preferably 60 to 120 °, more preferably 70 to 110 °.

The bottom portion 12 of the flat plate 1 may have a shape similar to that of the bottom portion such as a square or a triangle. The angle (inner angle) of both ends 13 of the bottom may be substantially a right angle, preferably 70 to 100 °, and more preferably 80 to 95 °. The length L (dimension from the lower end to the upper end) of the plate 1 is preferably 100 to 400 mm, more preferably 150 to 350 mm. The width W of the plate 1 is preferably 30 to 150 mm, more preferably 40 to 120 mm.

As such a trowel, as shown in FIG. 2, a trowel provided with a plate 1 and a handle 2 can be used. As shown in FIG. 2, the handle 2 may be installed on the upper surface 16 side of the flat plate 1 via a support member 3 or the like. The position of the handle 2 may be near the central portion 14 of the flat plate 1 or between the central portion 14 and the bottom portion 12.

In the present invention, it is desirable to perform the step of treating the unevenness of the coated surface as the step (3) following the steps (1) and (2). By such a step (3), the shape of the uneven pattern formed in the step (2) can be adjusted. In particular, by smoothing the surface layer of the coated surface, it is possible to impart roundness, smoothness, etc. to the uneven pattern. Examples of such a smoothing treatment include polishing after drying the coated surface, pressing before drying the coated surface, and the like. In the step (3), it is desirable to maintain the basic shape of the uneven pattern, and the depth of the uneven pattern after the treatment is preferably 1 to 10 mm, more preferably 2 to 8 mm.

Among these, as for the pressing before the coated surface is dried, a method of smoothing the coated surface using an instrument such as a roller, a brush, or a sponge while the coated surface is not dried can be mentioned. Since such a method is performed before the coated surface is undried, the construction period is shortened, and unlike polishing, dust is not generated, which is advantageous.

In the present invention, as the step (3), it is desirable to perform a step of tapping the coated surface with a wet instrument while the coated surface is not dried. In such a step (3), while the coated surface is undried, the coated surface is tapped with a wet instrument (hereinafter, also referred to as “tapping tool”). In the present invention, by this step (3), it is possible to impart smoothness to the surface while maintaining the depth of the uneven pattern formed in the above step (2). Such an effect is that the basic shape of the uneven pattern is not easily impaired by the characteristics of the covering material, the appropriate pressure on the coated surface by the tapping tool, and the vicinity of the coated surface surface layer by the use of the wet tapping tool. It is considered that the fact that the surface layer of the coated surface tends to be smooth due to the decrease in viscosity and the like contributes to this. It is difficult to obtain such an effect with an instrument such as a brush.

As such a tapping tool, a flexible one is preferable, and for example, a spongy material or a fibrous material is preferable. Specific examples of the tapping tool include dandelion, sponge, felt and the like. The surface shape of the tapping tool is not particularly limited, and may be any of a square, a triangle, a circle, an indeterminate form, and the like. The tapping tool may be provided with a handle or the like, if necessary.

Water and / or solvent can be used to moisten the tapper. In the present invention, it is desirable to moisten with at least water.

When hitting the coated surface with a hitting tool, the uneven pattern can be adjusted by appropriately changing the degree of wetting, the pressure at the time of hitting, the number of times, and the like. You can also hit while randomly changing the direction of the hitting tool. In such a step (3), it is desirable to hit the coated surface with a tapping tool for the entire coated surface (over the entire coated surface).

After such a step (3), the covering material can be dried. Drying may be preferably carried out at room temperature (0 to 40 ° C.).

In the present invention, the finishing material can be applied after the above steps. As such a finishing material, for example, a transparent finishing material, a colored finishing material, or the like can be used. Of these, when a colored finishing material is used, it is possible to finish with a desired color tone. Examples of the coloring finishing material include synthetic resin emulsion paint, glossy synthetic resin emulsion paint, non-aqueous dispersion type resin enamel, and multicolored pattern paint.

A known instrument can be used for applying the finishing material. As such an instrument, for example, a spray, a roller, a brush, a trowel and the like can be used. The amount of the finishing material applied may be appropriately set according to the type of finishing material to be used, the type of equipment, and the like. The finishing material may be dried preferably at room temperature (0 to 40 ° C.).

Examples are shown below to further clarify the features of the present invention.

(Example 1)
150 parts by weight of extender pigment (heavy calcium carbonate, average particle size 10 μm), coloring pigment (titanium oxide) to 200 parts by weight of water-based resin (acrylic resin emulsion, heating residue 50% by weight, minimum film formation temperature 20 ° C) , Average particle size 0.3 μm) is 30 parts by weight, Aggregate 1 (cold water stone, average particle size 0.2 mm) is 250 parts by weight, Aggregate 2 (silica sand, average particle size 0.5 mm) is 350 parts by weight, 14 parts by weight of the film-forming auxiliary, 90 parts by weight of water, 4 parts by weight of the thickener, and 3 parts by weight of the defoaming agent (heat residue 50% by weight) are uniformly mixed by a conventional method to prepare the coating material 1. Manufactured. In this coating material 1, the content of the powder or granular material is 71% by weight, the weight ratio of each powder or granular material (constitution pigment: coloring pigment: aggregate) is 100: 20: 400, the heating residue is 81% by weight, and the flow. The value was 135 mm.

A slate plate that has been pre-coated with an undercoat is coated with a coating material 1 ^{smoothly at 4 kg / m 2} , and while the coated surface is still undried, the trowel is pressed against the coated surface and the trowel is removed from the coated surface. Was pulled up. This operation was repeated while changing the location to form a random uneven pattern. The trowel has the form shown in FIGS. 1 and 2 (flat plate: made of stainless steel, flat plate thickness: 0.3 mm, tip apex angle: 90 °, flat plate length: 210 mm, flat plate width: 60 mm) was used. Then, while the coated surface was undried, the coated surface was tapped entirely with a sponge moistened with water, and then dried at 23 ° C. for 24 hours to form a film. From the above, a hump-like uneven pattern coating having a depth of about 3 to 4 mm and a smooth coating surface was obtained.

(Example 2)
240 parts by weight of extender pigment (same as above), 35 parts by weight of coloring pigment (same as above), 300 parts by weight of aggregate 1 (same as above), 350 parts by weight of aggregate 2 (same as above) with respect to 200 parts by weight of water-based resin (same as above). The coating material 2 was produced by uniformly mixing 14 parts by weight of a film-forming auxiliary, 86 parts by weight of water, 4 parts by weight of a thickener, and 3 parts by weight of a defoaming agent by a conventional method. In this coating material 2, the content of the powder or granular material is 75% by weight, the weight ratio of each powder or granular material (constitution pigment: coloring pigment: aggregate) is 100: 15: 271, the heating residue is 84% by weight, and the flow. The value was 115 mm.

A coating was formed in the same manner as in Example 1 except that the covering material 2 was used instead of the covering material 1. From the above, a hump-like uneven pattern having a depth of about 3 to 5 mm and a smooth surface of the coating film was obtained.

(Example 3)
For 200 parts by weight of water-based resin (same as above), 130 parts by weight of extender pigment (same as above), 20 parts by weight of coloring pigment (same as above), 180 parts by weight of aggregate 1 (same as above), and 280 parts by weight of aggregate 2 (same as above). The coating material 3 was produced by uniformly mixing 14 parts by weight of a film-forming auxiliary, 94 parts by weight of water, 4 parts by weight of a thickener, and 3 parts by weight of a defoaming agent by a conventional method. In this coating material 3, the content of the powder or granular material is 66% by weight, the weight ratio of each powder or granular material (constitution pigment: coloring pigment: aggregate) is 100: 15: 354, the heating residue is 77% by weight, and the flow. The value was 152 mm.

A coating was formed in the same manner as in Example 1 except that the covering material 3 was used instead of the covering material 1. From the above, a hump-like uneven pattern having a depth of about 2 to 3 mm and a smooth surface of the coating film was obtained.

Claims (9)

It is a method of forming a film having an uneven pattern, and is a method for forming a film having an uneven pattern.
(1) A coating material containing an aqueous resin and powder or granular material having a content of the powder or granular material of 30 to 90% by weight, a heating residue of 50 to 95% by weight, and a flow value of 100 to 180 mm is applied. Process,
(2) While the coated surface of the covering material is not dried, a flat plate is pressed against the coated surface and the flat plate is pulled up from the coated surface to impart irregularities having a depth of 1 to 10 mm to the coated surface. Process,
A method for forming a film, which comprises performing the above steps in order. Following the above (1) step and the above (2) step,
(3) The step of treating the unevenness of the coated surface,
The film forming method according to claim 1, wherein the above steps are performed in order. The film forming method according to claim 2, wherein the step (3) is a step of tapping the coated surface with a wet instrument while the coated surface is not dried. The film forming method according to claim 3, wherein the instrument used in the step (3) is a spongy material or a fibrous material. The film forming method according to claim 3, wherein the instrument used in the step (3) is at least one selected from dandelion, sponge, and felt. The powder or granular material contains an extender pigment, a color pigment, and an aggregate, and the weight ratio of the extender pigment, the color pigment, and the aggregate is 100: (1 to 100) :( 10 to 1000). The film forming method according to any one of claims 1 to 5. The film forming method according to any one of claims 1 to 6, wherein the material of the flat plate is one or more selected from metal, resin, and wood. The film forming method according to any one of claims 1 to 7, wherein the thickness of the flat plate is 0.1 to 1 mm. The film forming method according to any one of claims 1 to 8, wherein the flat plate has a tip portion having a sharp shape, and the tip portion has flexibility.

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