Formation method of decorative coating and decorative coating

Abstract

To provide a formation method of a highly aesthetic decorative coating surface having complex and natural shades of color tone.SOLUTION: The present invention is a formation method of a decorative coating having shades of color tone, which applies a coating material containing a resin component and scaly metal particles to a base material. The formation method includes applying the coating material in a first application direction to form an application part (p), and applying the coating material in an application direction different from the first application direction to form an application part (q). A pattern including the application part (p) and the application part (q) is formed.SELECTED DRAWING: None

Description

Technical Field

[0001] The present invention relates to a method for forming a novel decorative film.

Background Art

[0002] Conventionally, decorative films having various patterns have been formed on the walls of buildings, civil engineering structures, etc. In particular, in recent years, with the design of many buildings with high design quality, for example, various decorative films such as natural stone finish, wood grain finish, metallic finish, leather finish, porcelain (glaze) finish, antique finish, etc. are desired. As an example of such a decorative film, a decorative film formed by partially overlapping a plurality of coating materials to form a pattern can be mentioned.

[0003] For example, Patent Document 1 describes a method of applying a colored base paint over the entire surface and then applying a plurality of colored paints with different colors in a dotted pattern on that surface to finish with a multicolored pattern. However, in Patent Document 1 above, there is a possibility that the dotted pattern may be monotonous and result in an artificial finish.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] The present invention has been made in view of such problems, and an object thereof is to provide a method for forming a decorative film surface having a high aesthetic appearance with a complex and natural color shade.

Means for Solving the Problems

[0006] In order to solve such problems, as a result of intensive studies, the inventor of the present invention has conceived a method for forming a decorative film surface by applying a specific coating material to a base material by a specific coating method, and has completed the present invention.

[0007] That is, the present invention has the following features. 1. A method for forming a decorative coating having a shade of color, comprising: applying a coating material (excluding those containing colored aggregates) containing 5 to 80 parts by weight of Scaly metal particles with an average particle diameter of 1 to 80 μm to 100 parts by weight (in terms of solid content) of a synthetic resin onto a substrate; 、 applying the coating material in a first coating direction P to form a coated portion (p) in which the flaky metal particles are oriented in the coating direction P, and applying the coating material in a coating direction Q different from the first coating direction to form a coated portion (q) in which the flaky metal particles are oriented in the coating direction Q, The angle formed by the coating direction P and the coating direction Q is 5 degrees or more and less than 180 degrees, and forming a shade pattern of color including the coated portion (p) and the coated portion (q). A method for forming a decorative coating, characterized by the above. 2. The coating material is applied so that the coating part (p) and the coating part (q) intersect The method for forming a decorative coating according to 1., characterized by the above. 3. The method for forming a decorative coating according to 1. or 2., characterized by applying the coating material with a roller or a brush.

Effects of the Invention

[0008] In the present invention, a coating material containing a resin component and flaky metal particles is applied to a substrate, and by applying the coating material in a specific coating direction, a decorative coating surface with a high aesthetic appearance having a complex and natural shade of color can be obtained.

Embodiments for Carrying Out the Invention

[0009] Hereinafter, embodiments for carrying out the present invention will be described.

[0010] The present invention is a method for forming a decorative coating having a shade of color, characterized by applying a coating material containing a resin component and flaky metal particles to a substrate by a specific coating method.

[0011] First, the coating material of the present invention will be described. <Coating material> The coating material in the present invention is characterized by containing a synthetic resin (A) and flaky metal particles (B). Examples of the synthetic resin (A) (hereinafter also referred to as the “component (A)”) of the present invention include water-soluble resins, water-dispersible resins, solvent-soluble resins, solventless resins, non-aqueous dispersion resins, etc., or those obtained by combining these. These may have crosslinking reactivity, and their forms are not particularly limited, and they may be either one-component type or two-component type. In the present invention, in particular, water-dispersible resins and / or water-soluble resins are preferably used. Examples of the types of resins that can be used include cellulose, polyvinyl alcohol, ethylene resins, vinyl acetate resins, polyester resins, alkyd resins, vinyl chloride resins, epoxy resins, silicone resins, acrylic resins, urethane resins, acrylic silicone resins, fluororesins, etc., or composite systems thereof.

[0012] In the present invention, the flaky metal particles (hereinafter also referred to as the “component (B)”) are components that impart shading to the color tone of the formed coating film. The type of metal of the component (B) is not particularly limited, and examples thereof include titanium, iron, aluminum, zinc, tin, zirconium, cobalt, nickel, rhodium, gold, silver, platinum, etc. Further, those in which the above-mentioned metal is coated on a flaky substrate such as muscovite, synthetic mica, silica flake, or glass flake can be used. Furthermore, those in which the surface of these component (B) is colored can also be used. These can be used singly or in combination of two or more.

[0013] In the present invention, it is preferable to use aluminum flakes as the component (B). Thereby, shading can be easily formed in the color tone of the formed coating film. As the aluminum flakes, aluminum particles and those having them as a base material can be used. The aluminum flakes may be composed of only aluminum or may be composed of an alloy containing aluminum. The purity of aluminum in the aluminum flakes is not particularly limited. Further, the aluminum flakes may have a grinding aid attached thereto during the manufacturing process. As the grinding aid, an unsaturated fatty acid is usually used. Examples of the unsaturated fatty acid used herein include oleic acid, linoleic acid, linolenic acid, ricinoleic acid, elaidic acid, zoapatanic acid, gadoleic acid, and erucic acid.

[0014] Furthermore, in the present invention, it is preferable to use those in which a water-resistant film is formed on the surface of the aluminum flakes. Examples of the water-resistant film include films formed by treating with chromic acid, phosphoric acid, phosphates, phosphate esters, vanadates, vanadium oxide, molybdates, silica, silane coupling agents, and the like.

[0015] Also, in the present invention, either leafing type or non-leafing type aluminum flakes can be used. The leafing type aluminum flakes are those in which the aluminum flakes are surface-treated with stearic acid or the like, have low affinity with the coating material, float on the surface, and are uniformly oriented. On the other hand, the non-leafing type aluminum flakes are those in which the aluminum flakes are surface-treated with oleic acid or the like, have high affinity with the coating material, are dispersed inside, and are randomly oriented. In the present invention, leafing type aluminum flakes and non-leafing type aluminum flakes can also be mixed and used.

[0016] (B) component's average particle diameter is preferably 1 to 80 μm (more preferably 3 to 70 μm), and the average thickness is preferably 0.1 to 2.5 μm (preferably 0.2 to 2.0 μm). Also, the ratio of the average particle diameter to the average thickness (aspect ratio) is preferably 5 or more (more preferably 10 or more). Moreover, the upper limit is preferably 1000 or less (more preferably 500 or less). In such a case, natural shading can be more effectively formed in the color tone of the formed coating film.

[0017] Note that the average particle diameter can be measured using a laser diffraction particle size distribution measuring device. Also, the average thickness is a value obtained by directly measuring the thickness of about 50 (B) components from a cross-sectional photograph using a scanning electron microscope (SEM) and averaging them.

[0018] (B) component's mixing ratio is preferably 3 to 100 parts by weight (more preferably 5 to 80 parts by weight) with respect to 100 parts by weight (in terms of solid content) of (A) component. In such a case, a film with shading in the color tone is easily formed, and the effects of the present invention can be further enhanced.

[0019] The coating material of the present invention can be used including known coloring pigments, extender pigments, etc. in addition to the (B) component. Among these, examples of the coloring pigment include titanium oxide, zinc oxide, carbon black, lamp black, bone black, graphite, black iron oxide, copper chromium black, cobalt black, copper manganese iron black, red iron oxide, titanium yellow, fast yellow, benzimidazolone yellow, chrome green, cobalt green, phthalocyanine green, ultramarine, navy blue, cobalt blue, phthalocyanine blue, quinacridone violet, dioxazine violet, colored mica, pearl pigment, bright pigment, etc. By using one or more of these coloring pigments, it is possible to color in any hue.

[0020] Examples of extender pigments include, for example, heavy calcium carbonate, calcite, precipitated calcium carbonate, white carbon, talc, mica, kaolin, clay, pottery clay, china clay, diatomaceous earth, barite powder, barium sulfate, precipitated barium sulfate, silica sand, silica powder, quartz powder, resin beads, glass beads, hollow balloons, etc., and one or more of these can be used. By appropriately setting the type, mixing ratio, etc. of the extender pigment, the coating material can be adjusted to a desired glossiness.

[0021] In addition to the above components, the coating material of the present invention may contain known additives, such as aggregates, dyes, thickeners, wetting agents, antifreezing agents, film-forming aids, preservatives, fungicides, algicides, antibacterial agents, dispersants, defoaming agents, ultraviolet absorbers, light stabilizers, antioxidants, catalysts, diluting solvents, etc., within a range that does not significantly inhibit the effects of the present invention. The coating material can be produced by uniformly mixing the above-mentioned respective components by a conventional method.

[0022] <Film-forming method> The method for forming a decorative film of the present invention (hereinafter referred to as "film-forming method") is to apply the above coating material to a substrate. It is characterized by including applying the above coating material in a first coating direction P (hereinafter also referred to as "coating direction P") to form a coated portion (p), and applying the above coating material in a coating direction Q different from the first coating direction (hereinafter also referred to as "coating direction Q") to form a coated portion (q).

[0023] The decorative film formed according to the present invention includes a coated portion (p) and a coated portion (q), and can have a natural color shade. In the coated portion (p) of the decorative film of the present invention, the component (B) is oriented in the coating direction P, while in the coated portion (q), the component (B) is oriented in the coating direction Q. As a result, the reflection of light is different between the coated portion (p) and the coated portion (q), causing a shade in the film.

[0024] In the present invention, the shade of color tone is not particularly limited as long as a dark-colored part and a light-colored part are visually recognizable on the formed film surface. However, a mode having a coating part with a brightness difference ΔL* between the dark-colored part and the light-colored part of preferably 1 or more (more preferably 3 or more, still more preferably 5 or more, and particularly preferably 8 or more) is more suitable. The upper limit of the brightness difference ΔL* is not particularly limited, but is preferably 30 or less. In such a case, it is possible to form a decorative film surface with a high aesthetic property having a natural shade of color tone. Note that the brightness difference represents the brightness difference of the coating film surface in the L*, a*, b* color system defined in JIS Z 8729, and ΔL* is a value represented by the absolute value of [L* value of the dark-colored part - L* value of the light-colored part].

[0025] In the film forming method of the present invention, when forming the coating part (p), the coating direction P is not particularly limited, and it can be coated in any direction. Next, when forming the coating part (q), the coating direction Q of the coating material is not particularly limited as long as it is different from the coating direction P, and it can be coated in any direction. Also, the coating direction Q does not necessarily have to be a single direction, and a plurality of coating directions can be combined. Examples of such combinations of the coating direction P and the coating direction Q include combinations as shown in Table 1. Specifically, when the coating direction P is [left → right] as in Table 1-1, the coating direction Q may be one or more directions selected from [right → left, bottom → top, top → bottom, left (right) diagonal up → right (left) diagonal down, right (left) diagonal down → left (right) diagonal up]. Further, when applying the coating material, it may be applied in a straight line direction or in a curved line direction (drawing an arc). In the present invention, it is preferable that the coating direction Q has an angle with respect to the coating direction P, and it is preferable that the angle formed by the coating direction P and the coating direction Q is 5 degrees or more and less than 180 degrees. Thereby, the effect of the present invention can be further enhanced.

[0026] Further, in the film forming method of the present invention, it is sufficient that it includes the step (Q) of applying the coating material in the coating direction Q after the step (P) of applying the coating material in the coating direction P, and the steps (P) and (Q) can be repeated a plurality of times.

[0027] The decorative film formed according to the present invention includes the above-mentioned coating part (p) and the above-mentioned coating part (q). The pattern formed by the above-mentioned coating part (p) and the above-mentioned coating part (q) is, for example, · A pattern in which the coating part (p) and the coating part (q) are discontinuous (random), · A pattern in which the coating part (p) and the coating part (q) are continuous, · A pattern in which the coating part (p) and the coating part (q) have an overlapping part (pq), · A pattern combining the above, and the like. In the present invention, it is preferable that the coating part (p) and the coating part (q) have an overlapping part (pq). Furthermore, it is preferable that the overlapping part (pq) is formed by being coated so as to cross the coating material. Such an overlapping part (pq) is likely to cause diffuse reflection of light because the orientation of the component (B) becomes random or the density of the component (B) changes, and it is easily visually recognized as a dark color tone or low gloss compared with the coating part (p) or the coating part (q). As a result, the overlapping part (pq) can effectively form a dark-colored part, so that the effect of the present invention can be further enhanced.

[0028] In the film forming method of the present invention, the coating amount of the coating material may be appropriately set in consideration of the type and state of the substrate, the desired finish (pattern, etc.), etc., but preferably 30 to 500 g / m 2 (more preferably 80 to 400 g / m 2 , even more preferably 90 to 300 g / m 2 ). In such a case, the effect of the present invention can be sufficiently obtained.

[0029] The coating material can be diluted with various solvents during application. The dilution ratio of the coating material is preferably 0 to 50% by weight (more preferably 1 to 50% by weight, even more preferably 2 to 40% by weight) based on the coating material. In this case, a film with non-uniform color tone and / or gloss can be formed more efficiently. Also, the viscosity of the coating material during application is preferably 0.1 to 8 Pa·s (more preferably 0.5 to 6 Pa·s). In such a case, a film having a shade of color tone is likely to be formed. The viscosity is a value (the pointer value at the fourth rotation) measured using a BH-type viscometer (rotation speed 20 rpm) under standard conditions (temperature 23°C, relative humidity 50%).

[0030] When applying the coating material, as the coating tool, for example, a spray, a brush, a roller, a brush (including bristles, etc.), a pressing tool (including a tapping tool, etc.) can be used. Among these, examples of the roller include a fibrous roller, a porous (sponge-like) roller, etc., and examples of the pressing tool include those having a sponge, felt, woven fabric, non-woven fabric, etc. In the present invention, it is preferable to use a roller or a brush, and particularly, it is preferable to use a fibrous roller.

[0031] The fibrous roller used in the present invention is, for example, one having a fibrous layer provided on the outer surface of a cylindrical core material. The cylindrical core material has a cavity so that a handle having a shaft can be attached, and the handle can be attached to the cavity and used. The cylindrical core material is not particularly limited, but a core material made of plastic, wood, metal, etc. can be used. Also, in order to enhance the adhesion between the shaft of the handle and the core material, a reinforcing material made of plastic, rubber, glass, metal, fiber, etc. can be used between the shaft of the handle and the core material.

[0032] In the present invention, the thickness of the fibrous layer during drying when the fibrous roller does not contain a coating material is 2 mm or more and 15 mm or less (preferably 3 mm or more and 10 mm or less), and the thickness of the fibers is 5 μm or more and 150 μm or less (preferably 8 μm or more and 100 μm or less, more preferably 10 μm or more and 50 μm or less). By setting the thickness of the fibrous layer and the thickness of the fibers in this way, the effects of the present invention can be enhanced.

[0033] Also, the length of the fibers is preferably about 1 mm or more and 20 mm or less (preferably 2 mm or more and 15 mm or less, more preferably 3 mm or more and 10 mm or less). By using such a fibrous roller, it is possible to form a highly aesthetic decorative coating surface having a complex and natural color shade.

[0034] The base material in the present invention is preferably a base material surface such as a building or a civil engineering structure, particularly a base material constituting the surfaces of interior and exterior walls, ceilings, furniture, etc. Examples of such base materials include gypsum board, concrete, mortar, ceramic tiles, bricks, cement board, fiber-reinforced cement board, calcium silicate cement board, perlite board, ALC board, siding board, extruded board, plywood, wooden board, steel plate, plastic board, glass board, etc. The surfaces of these base materials may be those subjected to some surface treatment (for example, sealer, surfacer, filler, etc.), or those on which a coating film has already been formed, or those to which wallpaper has been pasted.

[0035] In the present invention, it is preferable to include a step of forming an underlayer in advance on the base material. The underlayer can be formed by applying an undercoat material containing a synthetic resin and a pigment. The undercoat material is preferably applied to the entire surface of the base material. As the coating method, various methods such as brushing, spray coating, and roller coating can be adopted. The coating amount is preferably 0.01 to 0.5 kg / m 2 (more preferably 0.05 to 0.4 kg / m 2 ). It is also possible to apply the coating in multiple times within such a coating amount range.

[0036] Also, in the method for forming the decorative film surface of the present invention, within a range that does not inhibit the effects of the present invention, (First step) A step of forming a decorative film surface by the above-described film-forming method, (Second step) As a second step, a step of discontinuously applying a second coating material to form a pattern, can be included. The second coating material is not particularly limited. For example, it may be the same coating material as the coating material (hereinafter referred to as the "first coating material") used in the first step, or may be a coating material of a different color and / or different type from the first coating material.

[0037] In the above second step, the timing of applying the second coating material is not particularly limited, but it is preferably after the first coating material (the previously applied coating material) has reached a non-fluid state. Thereby, each coating material is difficult to mix, a stable finish can be imparted, and a decorative film surface with high aesthetic properties can be obtained. In the present invention, the "non-fluid state" means a state in which the fluidity of the film is lost after applying the first coating material. Specifically, it means a state in which no bleeding occurs even when the second coating material is applied, or a state in which the coating materials are dried and cured to such an extent that they do not mix with each other. This "non-fluid state" also includes states such as touch-dry, semi-cured dry, and cured dry as defined in JIS K5400. In the present invention, it is preferable to apply the second coating material after the first coating material has become touch-dry (more preferably after semi-cured dry, and even more preferably after cured dry). In the present invention, drying and curing are preferably performed at room temperature (5 to 40°C).

[0038] The coating amount of the second coating material may be appropriately set according to the desired finish (such as a pattern). However, it is preferable that the coating amount of the second coating material is less than that of the first coating material, preferably 100 g / m 2 or less (more preferably 5 to 90 g / m 2 , even more preferably 10 to 80 g / m 2 ). When the coating amount of the second coating material satisfies the above range, a discontinuous film is easily formed, and a decorative film surface having a pattern in which the first film and the second film are mixed and intertwined can be stably formed.

[0039] As an application tool for applying the second coating material, for example, a spray, a roller, a brush (including brush hairs, etc.), a pressing tool (including a tapping tool, etc.) and the like can be used. Among these, as the roller, for example, a fibrous roller, a porous (sponge-like) roller, a patterned roller (for example, a roller brush described in JP-A-2016-032807), etc. can be mentioned, and as the pressing tool, for example, those having a sponge, felt, woven fabric, non-woven fabric, etc. can be used. Thereby, a decorative coating surface with high aesthetic properties having a good balance (arrangement) of patterns can be obtained.

[0040] In the method for forming the decorative coating surface of the present invention, as long as the effects of the present invention are not inhibited, for the purposes of surface protection, weather resistance improvement, stain resistance, etc., a clear coating material can be applied to the outermost surface to provide a clear layer.

[0041] <Decorative coating> The decorative coating of the present invention is a decorative coating having shades of color, and is formed by the above coating material and the above coating formation method. Specifically, the decorative coating of the present invention is one in which a pattern including coating portions (p) and (q) formed by applying a coating material containing a resin component and scaly metal particles can be visually recognized. The above coating portion (p) is formed by applying the above coating material in a first coating direction, and the above coating portion (q) is formed by applying the above coating material in a coating direction different from the first coating direction. Such a decorative coating including the coating portion (p) and the coating portion (q) has a complex and natural shade of color due to light reflection.

[0042] The decorative coating of the present invention preferably has a pattern including the coating portion (p), the coating portion (q), and an overlapping portion (pq), particularly, at least a part of the coating portion (p) and the coating portion (q) having an overlapping portion. Thereby, a coating having a more complex and natural shade of color and high aesthetic properties can be obtained.

[0043]

Example

[0044] Examples are shown below to clarify the features of the present invention.

[0045] The following materials were prepared as coating materials.

[0046] · Coating material 1 200 parts by weight of an acrylic resin emulsion (solid content: 50% by weight), 30 parts by weight of an aluminum pigment paste (aluminum flake content: 60% by weight), 20 parts by weight of additives (dispersant, defoaming agent, thickener, etc.), and 230 parts by weight of water were mixed and stirred by a conventional method to produce silver-based coating material 1. · Primer To 200 parts by weight of a synthetic resin emulsion (solid content 50% by weight), 140 parts by weight of titanium oxide, 40 parts by weight of talc, 60 parts by weight of kaolin, 1.5 parts by weight of carbon black, and 8 parts by weight of additives (dispersant, defoaming agent, thickener, etc.) were mixed and stirred by a conventional method to produce a primer (hue: gray).

[0047] (Example 1) The primer was applied to the entire surface of the base material (slate board) with a wool roller so that the application amount was 0.12 kg / m 2 and dried for 3 hours in a standard state to form a base layer. Next, after coating material 1 was applied with a fibrous roller in the coating direction P (Table 1: coating direction P1) to form a coated portion (p), it was applied with a fibrous roller in the coating direction Q (Table 1: coating direction Q4) to form a coated portion (q). While repeating these, on the base layer, a pattern in which the coated portions (p) and (q) were discontinuous (random) was formed (coating amount of coating material 1: 0.1 kg / m 2 ) and dried for 24 hours. All painting and drying were carried out in a standard state. By the above method, a decorative film surface with a complex and natural color shade was obtained on the gray base layer. In the obtained decorative film, the maximum value of the lightness difference ΔL* between the dark-colored part and the light-colored part was 16.2, and the minimum value was 3.2.

[0048] (Example 2) On the base material (slate board), apply an undercoat material with an application amount of 0.12 kg / m 2 using a wool roller so that the amount is as described, and dry it for 3 hours under standard conditions to form a base layer. Next, apply Coating Material 1 with a fibrous roller in the coating direction P (Table 1: Coating Direction P7) to form a coated portion (p). Then, apply it with a fibrous roller in the coating direction Q (Table 1: Coating Direction Q5) so as to have an overlapping portion with the coated portion (p) to form a coated portion (q). While repeating these, on the base layer, a pattern in which the coated portion (p), the coated portion (q), and the overlapping portion (pq) exist discontinuously (randomly) is formed (the application amount of Coating Material 1 is 0.1 kg / m 2 ), and it is dried for 24 hours. All painting and drying were carried out under standard conditions. By the above method, a decorative coating surface with a complex and natural color shade, especially having a dark-colored portion at the overlapping portion (pq), was obtained on the gray-based base layer. In the obtained decorative coating, the maximum value of the lightness difference ΔL* between the dark-colored portion and the light-colored portion was 18.1, and the minimum value was 5.2.

[0049]

Table 1

Claims

1. A method for forming a decorative coating having a shade of color, comprising: applying a coating material (excluding those containing colored aggregates) containing 5 to 80 parts by weight of scaly metal particles having an average particle diameter of 1 to 80 μm with respect to 100 parts by weight (in terms of solid content) of a synthetic resin to a substrate; applying the coating material in a first coating direction P to form a coated portion (p) in which the scaly metal particles are oriented in the coating direction P, and applying the coating material in a coating direction Q different from the first coating direction to form a coated portion (q) in which the scaly metal particles are oriented in the coating direction Q; the angle formed by the coating direction P and the coating direction Q being 5 degrees or more and less than 180 degrees; and forming a shade pattern of color including the coated portion (p) and the coated portion (q). A method for forming a decorative coating, characterized by the above.

2. The method for forming a decorative coating according to Claim 1, characterized in that the coating material is applied so that the coated portion (p) and the coated portion (q) intersect.

3. The method for forming a decorative coating according to Claim 1 or Claim 2, characterized in that the coating material is applied with a roller or a brush.

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