Film formation method

Abstract

To provide a film formation method which can form a film excellent in finishing property.SOLUTION: A film formation method includes a step [1] of coating a first coating material onto a substrate, and forming a first film, wherein the step [1] includes a step [1-1] of coating the first coating material, and a step [1-2] of leveling the film surface with a trowel, curing the film, and forming a first film, after the first coating material is in a non-fluid state, and the trowel includes a trowel plate and a handle, and the bottom surface and / or edge part of the trowel plate has a curved shape.SELECTED DRAWING: None

Description

[Technical Field]

[0001] The present invention relates to a coating formation method. [Background technology]

[0002] Conventionally, decorative coatings having various patterns have been formed on the wall surfaces of buildings, civil engineering structures, etc. Examples of such decorative coatings include natural stone, wood grain, metallic, pearl, leather, ceramic (glaze) and antique finishes.

[0003] Coating materials for forming decorative coatings include thick coating materials and thin coating materials. Thick coating materials can be used to create a rich and dignified decoration with a variety of patterns, such as unevenness and texture. On the other hand, thin-coat coating materials can be used to create simple decorations such as a single color finish, a two or more color finish, or a transfer pattern. However, thin-coat coating materials can pick up the unevenness of the base or show through, so base treatment is important.

[0004] For example, when used as a thin coating material, the finish of a coating film containing a glittering pigment is easily affected by the base, and in some cases the finish may pick up the unevenness of the base, resulting in unevenness and not achieving the desired glitter. For example, Patent Document 1 describes applying an enamel paint to form a primer before the metallic coating film forming process. Patent Document 2 describes applying a colored paint to a thickness greater than or equal to the hiding film thickness to form a primer before the metallic coating film forming process. Furthermore, Patent Document 3 describes applying a primer to the base layer multiple times, and then applying the metallic paint. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] Japanese Patent Application Publication No. 2017-087144 [Patent Document 2] Japanese Patent Publication No. 2022-066179 [Patent Document 3] Japanese Patent Application Laid-Open No. 2001-259514 Summary of the Invention [Problem to be solved by the invention]

[0006] However, as in Patent Documents 1 and 2, simply applying an enamel paint (colored paint) forms a primer coating film that follows the unevenness of the base, making it difficult to obtain a flat primer coating film, which may result in a poor finish of the metallic coating film. Furthermore, when a colored paint is applied so that the base is concealed, as in Patent Document 2, in order to obtain a thick concealing film, multiple coats are required, as with the primer in Patent Document 3, which is time-consuming and inefficient. [Means for solving the problem]

[0007] In order to solve these problems, the present inventors discovered a coating formation method including specific steps, and completed the present invention.

[0008] That is, the present invention has the following features. 1. A coating forming method comprising: [1] a step of applying a first coating material to a substrate to form a first coating; The above process [1] is [1-1] a step of applying a first coating material; [1-2] a step of leveling the coating surface with a trowel after the first coating material has become non-flowable and hardening the material to form a first coating; The trowel comprises a trowel plate and a handle; A coating forming method characterized in that the bottom surface and / or edge portion of the mortarboard has a curved shape. 2. The method for forming a coating according to 1., wherein in the step [1-2], the surface of the coating is leveled with a trowel so that the bottom edge of the trowel plate does not come into contact with the surface of the coating. 3. The coating forming method according to 1., wherein the first coating material contains a resin component and powder or granules, and the powder or granules contain a luster pigment. 4. The method for forming a coating according to 1., further comprising the step [2] of applying a second coating material to the first coating to form a second coating. 5. The coating forming method according to 4., wherein the second coating material contains a resin component and powder or granules, and the powder or granules contain a luster pigment. 6. The coating forming method according to 4., wherein the step [2] includes a step of applying a second coating material to impart a pattern. [Effects of the Invention]

[0009] The coating forming method of the present invention can form a coating with excellent finish. [Brief explanation of the drawings]

[0010] [Figure 1] 1 shows an example of a trowel used in the present invention, where (a) is a front view, (b) is an X-X' cross-sectional view of (a), and (c) is a Y-Y' cross-sectional view of (a). [Figure 2] 2 shows an example of a trowel used in the present invention, where (a) is a front view, (b) is an X-X' cross-sectional view of (a), and (c) is a Y-Y' cross-sectional view of (a). [Figure 3] FIG. 3 shows an example in which the trowel shown in FIG. 1 or FIG. 2 is used. [Figure 4] 4 shows an example of a trowel used in the present invention, where (a) is a front view, (b) is an X-X' cross-sectional view of (a), and (c) is a Y-Y' cross-sectional view of (a). [Figure 5] 5 shows an example of a trowel used in the present invention, where (a) is a front view, (b) is an X-X' cross-sectional view of (a), and (c) is a Y-Y' cross-sectional view of (a). [Figure 6] FIG. 6 shows an example in which the trowel shown in FIG. 4 or FIG. 5 is used. [Figure 7] FIG. 7 shows an example of step [1] of the coating formation method of the present invention. [Figure 8]FIG. 8 shows an example of step [2] of the coating formation method of the present invention. [Explanation of symbols]

[0011] 1: Trowel 11: Mortarboard 11a: Bottom of the mortarboard 11b: Edge of mortarboard (outer peripheral edge) 12: Handle 13:Connection part 2: Base 3: Film DETAILED DESCRIPTION OF THE INVENTION

[0012] Hereinafter, an embodiment of the present invention will be described.

[0013] The present invention provides a coating formation method, [1] a step of applying a first coating material to a substrate to form a first coating; The above process [1] is [1-1] a step of applying a first coating material; [1-2] a step of leveling the coating surface with a trowel after the first coating material has become non-flowable and hardening the material to form a first coating; The trowel comprises a trowel plate and a handle; The mortarboard is characterized in that the bottom surface and / or edge portion thereof has a curved shape.

[0014] The present invention provides a coating formation method that can efficiently flatten the surface of a substrate, thereby improving the finish. In particular, when a thin coating material is applied as a finishing material, the finish is easily affected by the substrate, and in some cases, the finish may pick up unevenness in the substrate, resulting in unevenness and making it impossible to achieve the desired design. In contrast, by including the step [1] before applying the thin-coat coating material, in which the first coating material is applied, and after the first coating material has become non-fluid, the coating surface is leveled with a trowel and allowed to harden, the base surface can be efficiently flattened, and a decorative coating with the desired design can be formed in a finishing method using a thin-coat finishing coating material.

[0015] The above-mentioned [1] step is characterized by including the [1-1] step of applying the first coating material, and the [1-2] step of leveling the coating surface with a trowel after the first coating material has become non-fluid, and then hardening it to form the first coating.

[0016] In the above step [1-1], the first coating material is preferably applied to the entire surface of the base. The amount of the first coating material to be applied may be determined appropriately taking into consideration the type and condition of the substrate, the finish, etc., but is preferably 300 g / m 2 or less, more preferably 5 to 200 g / m 2 (More preferably 10 to 100 g / m 2 , particularly preferably 15 to 80 g / m 2 The amount of the first coating material applied is preferably 2 to 200 g / m2 in terms of solid content. 2 (More preferably 3 to 95 g / m 2 , and more preferably 5 to 75 g / m 2 ) When applying the first coating material, it may be diluted with a dilution solvent (for example, water, etc.), and in this case, the amount applied is the amount of the first coating material applied after dilution. When the applied amount of the first coating material satisfies the above range, the effects of the present invention can be sufficiently obtained. Note that in the present invention, "a to b" is synonymous with "a or more and b or less."

[0017] Examples of application tools for applying the first covering material include sprays, rollers, brushes (including paintbrushes), etc. Among these, examples of rollers include fibrous rollers and porous (sponge) rollers.

[0018] Next, in the step [1-2], after the first coating material has become non-fluid, the coating surface is smoothed with a trowel and hardened to form the first coating. In the present invention, the "non-flowing state" refers to a state in which the coating surface loses fluidity after application of the first coating material, and refers to a state before the coating is completely cured and dried. This "non-flowing state" includes the touch-dry and semi-cured and dried states specified in JIS K5400. The time required for the first coating material to reach a non-fluid state varies depending on the composition of the first coating material, the amount applied, the drying temperature, etc., but is preferably about 1 to 15 minutes (more preferably 3 to 10 minutes) after application. In the present invention, drying and curing may be preferably carried out at room temperature (5 to 40°C).

[0019] In the present invention, after the first coating material has become non-flowable (preferably when it is dry to the touch or semi-hardened and dry, more preferably when it is dry to the touch), the surface of the first coating can be smoothed by smoothing the surface with a trowel. Although the mechanism of action is not limited to this, when the first coating material is in a non-fluid state, the coating material can be spread with a trowel even when the surface of the first coating is smoothed with a trowel, even though the first coating material is in a dry state where it barely adheres to the trowel. This makes it difficult for trowel marks to remain, and the first coating can efficiently fill in minute irregularities present on the surface of the base. This allows the surface of the first coating to be smoothed.

[0020] The trowel used in the step [1-2] is characterized by having at least a trowel plate and a handle, and the bottom surface and / or edge of the trowel plate having a curved shape. If the bottom surface of the mortarboard is flat, there is a risk of problems such as scraping off the first coating material with the outer peripheral edge (edge) of the mortarboard or leaving trowel marks, and skilled techniques may be required to flatten the coating. In contrast, if the bottom surface and / or edge of the mortarboard is curved, as in the trowel used in the present invention, the edge (outer peripheral edge) of the mortarboard is less likely to come into contact with the coating surface, reducing the occurrence of the above problems and allowing the first coating material to be flattened easily and efficiently.

[0021] The mortarboard may be made of, for example, metal, wood, plastic, ceramic, etc. The present invention is particularly advantageous when a metal mortarboard is used. Examples of metal mortarboards include iron, steel, aluminum, and stainless steel.

[0022] Specifically, the shape of the bottom of the mortarboard may be, for example, a triangle, a rectangle, a pentagon, a polygon, or any of these shapes with rounded corners, or a circle, an ellipse, etc. In the present invention, a circle or an ellipse is particularly preferred. The thickness of the mortarboard is preferably 0.1 to 20 mm (more preferably 0.2 to 15 mm).

[0023] The material of the handle is not particularly limited, and examples thereof include metal, wood, plastic, and ceramic. The shape of the handle is also not particularly limited, and although a rod-shaped handle is shown in Fig. 1, U-shaped, V-shaped, semicircular, and other shapes are also possible. The handle may be pre-connected to the support or may be detachable, and the angle may be changeable.

[0024] An example of a trowel suitable for the coating formation method of the present invention is shown in Figures 1 and 2. Also, Figure 3 shows an example in which the trowel shown in Figure 1 or 2 is used.

[0025] FIG. 1 shows an example of a trowel suitable for the coating formation method of the present invention, where (a) is a front view, (b) is an X-X' cross-sectional view of (a), and (c) is a Y-Y' cross-sectional view of (a). FIG. 2 shows another example of a trowel suitable for the coating formation method of the present invention, where (a) is a front view, (b) is an X-X' cross-sectional view of (a), and (c) is a Y-Y' cross-sectional view of (a). As shown in Figures 1 and 2, the trowel of the present invention comprises a trowel plate [1] and a handle

[12] , which are connected by a connecting part

[13] . The present invention is characterized in that the bottom edge (11b in Fig. 1) of the mortarboard

[11] has a curved shape as shown in Figs. 1 and 2(b) and (c). In this case, the bottom surface [11a] of the mortarboard

[11] can be flat. Furthermore, as shown in Figs. 1 and 2(b) and (c), it is preferable that the edge (outer peripheral end) of the mortarboard [11b in Figs. 1 and 2] has a curved shape so as not to come into contact with the surface of the coating [3] as shown in Fig. 3.

[0026] 1 and 2, even if the bottom surface of the mortarboard is flat (flat plate-like), if the edge (outer peripheral edge) is curved, the edge (outer peripheral edge) of the mortarboard is less likely to come into contact with the coating surface, reducing the occurrence of problems such as scraping off the first coating material with the edge (outer peripheral edge) of the mortarboard or leaving trowel marks. Furthermore, if the bottom surface of the mortarboard is flat, the first coating material can be easily and efficiently flattened.

[0027] Another example of a trowel suitable for the coating formation method of the present invention is shown in Figures 4 and 5. Also, Figure 6 shows an example in which the trowel shown in Figure 4 or 5 is used.

[0028] FIG. 4 shows another example of a trowel suitable for the coating formation method of the present invention, where (a) is a front view, (b) is an X-X' cross-sectional view of (a), and (c) is a Y-Y' cross-sectional view of (a). FIG. 5 shows another example of a trowel suitable for the coating formation method of the present invention, where (a) is a front view, (b) is an X-X' cross-sectional view of (a), and (c) is a Y-Y' cross-sectional view of (a). As shown in Figures 4 and 5, the trowel of the present invention comprises a trowel plate [1] and a handle

[12] , which are connected by a connecting part

[13] . The present invention is characterized in that the bottom surface [11a] of the mortarboard

[11] has a curved shape (convex curved shape) as shown in (b) and (c) of Figures 4 and 5. Also, as shown in (b) and (c) of Figures 4 and 5, it is preferable that the edge (outer peripheral end) of the mortarboard [11b in Figures 4 and 5] has a curved shape that is curved so as not to come into contact with the surface of the coating [3] as shown in Figure 6.

[0029] 4 and 5, when the bottom surface of the mortarboard is curved (convex), the edge (outer peripheral edge) of the mortarboard is less likely to come into contact with the coating surface, reducing the occurrence of problems such as the edge (outer peripheral edge) of the mortarboard scraping off the first coating material or leaving trowel marks, and the coating can be easily and efficiently flattened without requiring skilled techniques. Furthermore, when the edge (outer peripheral edge) of the mortarboard is curved, the edge (outer peripheral edge) of the mortarboard is even less likely to come into contact with the coating surface, making it possible to more easily and efficiently flatten the first coating material.

[0030] In the above step [1-2], when smoothing the surface of the first coating with the trowel, the trowel can be moved as desired to smooth and flatten the surface. For example, the first coating surface can be pressed with the trowel to smooth it, or the coating surface can be rubbed with the trowel to smooth it. In addition, when leveling the surface of the first coating with the trowel, water can be used to adjust the non-flowing state of the coating surface (for example, by spraying water on the surface of the first coating or by applying water to the bottom of the trowel board).

[0031] In the present invention, in the step [1-2], it is preferable to smooth the surface of the coating with a trowel so that the bottom edge of the trowel plate does not come into contact with the surface of the coating. Furthermore, the contact portion of the bottom surface of the mortarboard that comes into contact with the coating surface is preferably the central region of the bottom surface of the mortarboard (the region extending from the center toward the outer periphery). Furthermore, the area of ​​the bottom surface of the mortarboard that contacts the coating surface is preferably 10 to 98% (more preferably 20 to 95%) of the area of ​​the bottom surface of the mortarboard. In this case, coating marks of the first coating and irregularities resulting from the base can be efficiently smoothed.

[0032] Furthermore, when smoothing the surface of the first coating with the trowel in the above step [1-2], it is preferable to smooth the surface by moving the trowel in a circular motion, for example, as shown in Fig. 7. Furthermore, it is preferable to move the trowel continuously without removing the bottom surface of the trowel plate from the surface of the first coating. This makes it possible to efficiently smooth out the application marks of the first coating and irregularities resulting from the base material.

[0033] In the present invention, after the first coating material is planarized and cured to form the first coating as described above, the following step [2] can be carried out as the next step. The interval between steps is preferably 20 minutes to 10 days (more preferably 30 minutes to 8 days, and even more preferably 1 hour to 7 days). In the present invention, drying and curing can be preferably carried out at room temperature (5 to 40°C).

[0034] The step [2] of the present invention is a step of applying a second coating material to the first coating surface formed in the step [1] above to form a second coating. In the above step [2], the second coating material may be applied according to the desired design, and may be applied, for example, to the entire surface of the first coating film or partially (discontinuously).

[0035] In the present invention, step [2] preferably includes a step of applying a second coating material to impart a pattern. The method of imparting the pattern is not particularly limited, and examples include a method of applying the second coating material to the entire surface of the first coating film and then imparting the pattern, or a method of applying the second coating material partially (discontinuously) by various application methods to impart the pattern.

[0036] In the present invention, it is preferable to include a step of applying a second coating material to the first coating, then applying a pattern to the coating surface with a trowel and curing the pattern. Specifically, the above step [2] is a step [2-1] of applying a second coating material to the entire surface of the first coating; It is preferable to include a step [2-2] of applying a pattern to the coating surface of the second coating material with a trowel and curing it to form a second coating.

[0037] In the above step [2-1], the amount of the second coating material to be applied may be appropriately determined taking into consideration the type and condition of the surface to be coated, the finish, etc., but is preferably 5 to 500 g / m 2 (More preferably 10 to 400 g / m 2 , and more preferably 15 to 300 g / m 2 The amount of the second coating material applied is preferably 2 to 450 g / m2 in terms of solid content.2 (More preferably 4 to 400 g / m 2 , and more preferably 5 to 300 g / m 2 ) and can be set within the above range taking into consideration the type and condition of the surface to be coated, the finish, etc. When applying the second coating material, it may be diluted with a dilution solvent (for example, water, etc.), and in this case, the amount applied is the amount of the second coating material applied after dilution. When the amount of the second coating material applied is within the above range, a coating having the desired design can be formed.

[0038] Examples of application tools for applying the second covering material include sprays, rollers, brushes (including paintbrushes), etc. Among these, examples of rollers include fibrous rollers and porous (sponge) rollers.

[0039] The trowel used in the above step [2-2] is not particularly limited, but it is preferable to use the same trowel as that used in the above step [1-2]. In addition, in the step [2-2], it is preferable to apply the pattern immediately after the second coating material is applied or after it has become non-fluid (dry to the touch or semi-hardened and dry). In the present invention, it is preferable to apply a pattern with a trowel immediately after applying the second coating material (preferably within 5 minutes), which allows the desired pattern to be applied satisfactorily. Furthermore, by applying a pattern with a trowel immediately after applying the second coating material, and continuing to apply the pattern with a trowel even after the second coating material has become non-flowable, it is possible to apply a desired pattern and flatten the second coating, resulting in a finish with excellent aesthetics. In particular, with the present invention, even when the amount of second coating material applied is small, it is possible to apply a desired pattern and flatten the second coating, resulting in a finish with excellent aesthetics.

[0040] When applying a pattern to the second coating using the trowel, the pattern can be applied by moving the trowel as desired to smooth it out. For example, the surface of the second coating can be pressed down with the trowel to smooth it out, or the surface of the coating can be rubbed with the trowel to smooth it out. In the present invention, it is preferable to move the trowel in a circular motion as shown in FIG. 7 (more preferably, in a figure-eight motion as shown in FIG. 8). Furthermore, it is preferable to move the trowel continuously without removing the bottom surface of the trowel plate from the surface of the second coating. Furthermore, when applying a pattern to the surface of the second coating using the trowel, the non-flowing state of the coating surface can be adjusted by adding water (for example, by spraying water on the surface of the second coating or by applying water to the bottom surface of the trowel plate). This method allows for the application of patterns that correspond to the direction of trowel movement. Furthermore, the second coating can be flattened, and even when a thin coating material is used, a highly aesthetically pleasing finish can be achieved. Furthermore, the thin coating type finishing method of the present invention is also advantageous in repainting due to renovations, recycling of substrates, etc.

[0041] Each constituent material is shown below. <Base> The substrate is not particularly limited, but may mainly be a substrate that constitutes the wall surface of a building, civil engineering structure, etc., such as concrete, cement, mortar, cement board, hard wood chip cement board, slate board, calcium silicate board, gypsum board, ALC board, extrusion molded board, fiber reinforced cement board, siding board, ceramic board, metal board, plywood, etc. The base in the present invention may be a substrate as described above that has undergone some kind of surface treatment, or may be a substrate on which a coating film has already been formed or on which wallpaper has been pasted. Furthermore, a primer or the like may be applied to the surface of the substrate before the application of the first covering material. Examples of such primers include known primers (e.g., sealers, surfacers, fillers, etc.). The color tone of such primers can be appropriately set, and for example, they can be the same color or the same color as the first covering material.

[0042] The coating formation method of the present invention can form a decorative coating having a desired design without being affected by the unevenness of the base. In the present invention, the unevenness of the base includes, for example, various uneven patterns and irregularities formed on the surface of the substrate, unevenness on the coating surface formed by a primer, paint marks (roller marks), etc.

[0043] <First covering material> The first coating material may contain a resin component, or a resin component and powder or granules.

[0044] Examples of resin components include water-soluble resins, water-dispersible resins, solvent-soluble resins, solventless resins, non-water-dispersible resins, and the like, as well as combinations of these. These may be crosslinkable, and their form is not particularly limited, and may be either a one-component or two-component type. In the present invention, water-dispersible resins and / or water-soluble resins are particularly preferred. Examples of resins that can be used include cellulose, polyvinyl alcohol, ethylene resin, vinyl acetate resin, polyester resin, alkyd resin, vinyl chloride resin, epoxy resin, silicone resin, acrylic resin, urethane resin, acrylic silicone resin, fluororesin, and the like, as well as composites of these.

[0045] As the powder or granule, for example, color pigments, extender pigments, luster pigments, etc. can be used. Examples of color pigments include organic pigments and inorganic pigments. Examples of organic pigments include phthalocyanine pigments such as phthalocyanine blue and phthalocyanine green, azo pigments such as monoazo red, fast yellow, permanent yellow, and disazo yellow, perylene pigments such as perylene red, quinacridone pigments such as quinacridone red, isoindolinone pigments, methine azomethine pigments, benzimidazolone pigments, and dioxazine pigments. Examples of inorganic pigments include titanium oxide, tin oxide, zinc oxide, iron oxide, carbon black, lamp black, bone black, graphite, black iron oxide, copper chromium black, cobalt black, copper manganese iron black, red iron oxide, yellow iron oxide, titanium yellow, chrome green, cobalt green, ultramarine blue, Prussian blue, cobalt blue, indium oxide, bismuth oxide, and tungsten oxide.

[0046] The average particle size of the color pigment is preferably 2 μm or less (more preferably 0.01 to 1 μm), and the average particle size of the color pigment is a value measured by a laser diffraction particle size distribution measuring device.

[0047] Examples of extender pigments include heavy calcium carbonate, kansuiite, light calcium carbonate, white carbon, kaolin, china clay, sericite, marlite, boehmite, silica gel, zeolite, alumina, allophane, diatomaceous earth, zeolite, siliceous shale, sepiolite, attapulgite, montmorillonite, zonolite, imogolite, barite powder, barium sulfate, precipitated barium sulfate, silica sand, silica powder, quartz powder, resin beads, porous resin beads, glass beads, hollow balloons, and the like, and one or more of these may be used.

[0048] The average particle size of the extender pigment is preferably 1 to 100 μm (more preferably 3 to 80 μm, and even more preferably 5 to 50 μm). The average particle size of the granular particles is a value measured by a laser diffraction particle size distribution measuring device.

[0049] Examples of the luster pigment include pearl pigments, metallic pigments, and flat pigments. Examples of pearl pigments include interference pearl pigments (polarized pearl pigments), white (silver) pearl pigments, and colored pearl pigments. Interference pearl pigments are made by covering the surface of scale-like (foil-like) base particles made of mica, aluminum, glass, etc. with a coating layer made of a colorless, highly refractive material such as titanium dioxide, and the reflected light and transmitted light change depending on the thickness of the coating layer, resulting in various interference colors. White pearl pigments are made by covering the surface of scale-like (foil-like) base particles such as mica, aluminum, or glass with a coating layer made of a colorless, high-refractive-index material such as titanium dioxide.The coating layer is thinner than interference pearl pigments, and they reflect almost all wavelengths of light, so they appear white or silvery. Colored pearl pigments are chromatic, and are formed by coating the surface of scaly (foil-like) base particles of mica, aluminum, glass, etc. with a colored high refractive index material such as ferric oxide as a coating layer. Examples include white pearl pigments that are further coated with a colored high refractive index material such as ferric oxide or other colored pigments, or pigments or other colorants added to the coating layer. Examples of metallic pigments include those made of scaly (foil) particles of metals such as aluminum, brass, tin, gold, silver, and copper. The flat pigments are scaly (foil-like) pigments such as pearl oyster shells, basic lead carbonate, bismuth oxychloride, talc, clay, china clay, mica, and glass flakes, and the particle surfaces are not covered with a coating layer. Compared with the above-mentioned pearl pigments and metallic pigments, these pigments have a softer sense of brilliance. These may be used alone or in combination of two or more.

[0050] The average particle size of the bright pigment is preferably 1 to 300 μm (more preferably 5 to 250 μm, and even more preferably 10 to 200 μm). The average particle size of the bright pigment is a value measured by a laser diffraction particle size distribution analyzer.

[0051] In the first coating material of the present invention, it is preferable that the powder or granule contains a glittering pigment. The glittering pigment has a scaly shape, which allows the first coating material to be efficiently spread out in step [1] and efficiently form a flattened coating. The mechanism of this action is not particularly limited, but when the first coating material contains a glittering pigment, the workability of the trowel is improved and the glittering pigment is easily aligned by spreading it with the trowel in a non-fluid state, allowing the flattened coating to be efficiently formed.

[0052] The bright pigment of the present invention is not particularly limited, but is preferably a particle having an aspect ratio (ratio of "minor axis / thickness") of 1.5 to 2000 (more preferably 2 to 1200, and even more preferably 3 to 500). The ratio of the minor axis to the major axis (minor axis / major axis) is preferably 0.3 to 1 (more preferably 0.4 to 1, and even more preferably 0.5 to 1). The terms "minor axis," "major axis," and "thickness" used herein are calculated by placing the bright pigment stably on a horizontal surface, observing it from above using a microscope, and taking the length of the shortest part as the "minor axis," the length of the longest part as the "major axis," and the maximum height from the bottom as the "thickness."

[0053] The first coating material of the present invention can also contain one or more powders selected from color pigments and extender pigments, which allows the first coating to have a desired color tone and gloss. The content of the color pigment in the first coating material is preferably 0 to 15 parts by mass (more preferably 0.1 to 10 parts by mass, and even more preferably 0.3 to 8 parts by mass) relative to 100 parts by mass of the solid content of the resin component. The content of the extender pigment in the first coating material is preferably 0 to 100 parts by mass (more preferably 1 to 80 parts by mass, and even more preferably 3 to 50 parts by mass) per 100 parts by mass of the solid content of the resin component.

[0054] The first coating material of the present invention preferably contains a porous powder as the extender pigment. This allows the first coating material to be efficiently spread in step [1]. While the mechanism of this action is not particularly limited, the moisture-retaining properties of the porous powder allow the first coating material to be kept dry enough to prevent it from adhering to the trowel, allowing the coating material to be efficiently spread. This reduces the likelihood of leaving trowel marks and allows the first coating to more efficiently fill in minute irregularities present on the base surface. This allows the first coating surface to be flattened. This is also advantageous when adjusting the non-flowing state of the coating surface by adding water when smoothing the first coating surface with the trowel.

[0055] Examples of such porous powders include the powder-like extender pigments mentioned above, such as zeolite, diatomaceous earth, marlite, boehmite, silica gel, zeolite, alumina, allophane, diatomaceous earth, siliceous shale, sepiolite, attapulgite, montmorillonite, zonolite, imogolite, and porous resin beads. These can be used alone or in combination of two or more. In the present invention, one or more selected from zeolite, diatomaceous earth, and silica gel are particularly preferred.

[0056] The average particle size of the porous powder or granule is preferably 5 to 100 μm (more preferably 8 to 80 μm, and even more preferably 10 to 50 μm). The average particle size of the porous powder or granule is a value measured by a laser diffraction particle size distribution analyzer.

[0057] The content of the powder or granules in the first coating material is preferably 10 to 500 parts by mass (more preferably 30 to 300 parts by mass, and even more preferably 50 to 200 parts by mass) relative to 100 parts by mass of the solid content of the resin component. Furthermore, the amount of the luster pigment is preferably 70 to 100% by mass (more preferably 75 to 98% by mass, and even more preferably 80 to 95% by mass) of the total amount of the powder or granules. If the amount of the luster pigment is within this range, it is easy to efficiently form a flat coating film and also easy to obtain a luster pattern.

[0058] In addition to the above components, the first coating material of the present invention may contain known additives, such as dyes, thickeners, wetting agents, antifreeze agents, film-forming aids, preservatives, antifungal agents, anti-algae agents, antibacterial agents, dispersants, antifoaming agents, UV absorbers, light stabilizers, antioxidants, catalysts, dilution solvents, etc., within limits that do not significantly impair the effects of the present invention. The coating material can be produced by uniformly mixing the above components using a conventional method.

[0059] The solid content of the first coating material of the present invention is preferably 30 to 95% by mass (more preferably 35 to 90% by mass). Furthermore, in the above step [1-1], when the first coating material is applied, it can be diluted with a dilution solvent (e.g., water), and the solid content at the time of application (after dilution) is preferably 20 to 80% by mass (more preferably 25 to 60% by mass). In such a case, the effects of the present invention can be fully exhibited.

[0060] The hiding rate of the first coating material is preferably 60% or more (more preferably 70% or more, even more preferably 80% or more, and particularly preferably 90% or more). In such a case, the substrate can be sufficiently hidden, and a coating with excellent aesthetics can be formed. The hiding rate is a value calculated by the following formula after measuring the visual reflectance of a test piece obtained by applying the first covering material to a hiding rate test paper using a film applicator (gap of 300 μm) and drying it under standard conditions for 24 hours. <expression> Concealment rate (%) = (visual reflectance of paint film on black background) / (visual reflectance of paint film on white background) x 100

[0061] <Second covering material> The second coating material may contain a resin component, or a resin component and powder or granules.

[0062] The resin component and powder particles may be the same as those described above for the first coating material.

[0063] In the second coating material of the present invention, it is preferable that the powder or granule contains a luster pigment. The luster pigment has a scaly shape, which allows the luster pigment in the second coating material to be oriented in the direction of trowel movement in step [2-2], thereby imparting a pattern. Furthermore, the second coating can be flattened, resulting in a finish with excellent aesthetics. Furthermore, because the luster pigment in the second coating material is oriented in the direction of trowel movement, it is possible to impart a luster-like, highly aesthetic pattern, such as a velvet-like or suede-like pattern.

[0064] The content of the luster pigment in the second coating material is preferably 10 to 500 parts by mass (more preferably 30 to 300 parts by mass) per 100 parts by mass of the solid content of the resin component, which allows the formation of a coating film with excellent aesthetic appearance.

[0065] The second coating material of the present invention can contain the color pigment and extender pigment in addition to the luster pigment, thereby allowing desired color tone, luster, etc. to be achieved. The content of the color pigment in the second coating material is preferably 0 to 15 parts by mass (more preferably 0.1 to 10 parts by mass, and even more preferably 0.3 to 8 parts by mass) per 100 parts by mass of the solid content of the resin component. The content of the extender pigment in the second coating material is preferably 0 to 100 parts by mass (more preferably 1 to 80 parts by mass, and even more preferably 3 to 50 parts by mass) per 100 parts by mass of the solid content of the resin component.

[0066] The second coating material of the present invention preferably contains the porous powder or granules described above as an extender pigment. This allows for efficient application of a pattern in step [2]. While the mechanism of this action is not particularly limited, the moisture-retaining properties of the porous powder or granules allow the second coating material to be kept in a dry state sufficient to prevent it from adhering to the trowel during the pattern application process, allowing the coating material to be efficiently spread out while the pattern is applied. This allows for the desired pattern to be applied while the second coating film is flattened, resulting in a finish with excellent aesthetics.

[0067] In addition to the above components, the second coating material of the present invention may contain known additives, such as dyes, thickeners, wetting agents, antifreeze agents, film-forming aids, preservatives, antifungal agents, anti-algae agents, antibacterial agents, dispersants, antifoaming agents, UV absorbers, light stabilizers, antioxidants, catalysts, dilution solvents, etc., within limits that do not significantly impair the effects of the present invention. The coating material can be produced by uniformly mixing the above components using a conventional method.

[0068] The solid content of the second coating material of the present invention is preferably 30 to 95 mass % (more preferably 35 to 90 mass %). Furthermore, in the above step [2-1], when the second coating material is applied, it can be diluted with a dilution solvent (e.g., water, etc.). The solid content at the time of application (after dilution) is preferably 25 to 93 mass % (more preferably 18 to 90 mass %). In the present invention, it is preferable to set the solid content at the time of application of the second coating material to be higher than the solid content at the time of application of the first coating material. In such a case, a finish with excellent aesthetic appearance can be obtained.

[0069] The hiding rate of the second covering material is preferably 80% or more (more preferably 85% or more, and even more preferably 90% or more). The hiding rate is a value calculated by the following formula after measuring the visual reflectance of a test piece obtained by applying the second covering material to a hiding rate test paper using a film applicator (gap of 300 μm) and drying it under standard conditions for 24 hours. <expression> Concealment rate (%) = (visual reflectance of paint film on black background) / (visual reflectance of paint film on white background) x 100

[0070] In the present invention, the first and second coating materials may be the same material, which allows for the formation of a coating with even more excellent aesthetics and is advantageous in terms of workability, cost, etc. [Example]

[0071] The following examples will be given to clarify the features of the present invention, but the present invention is not limited to these examples.

[0072] The coating materials A to L were prepared by using the raw materials shown in Table 1 and mixing them uniformly in the formulation shown in Table 2 according to a standard method.

[0073] [Table 1]

[0074] [Table 2]

[0075] For the base 1, the base material (slate board) was coated with a primer (pale pink) at a rate of 150 g / m 2 The paint was applied to the entire surface with a roller (using a fiber roller), allowed to dry for 2 hours, and a pale pink coating was formed before use.

[0076] For the base 2, a primer (yellow) was applied to the base material (slate board) at a rate of 150 g / m 2 The paint was applied to the entire surface with a roller (using a fiber roller), and allowed to dry for 2 hours to form a yellowish coating which was then used.

[0077] For the base 3, a primer (red) was applied to the base material (slate board) at a rate of 150 g / m 2 The paint was applied to the entire surface with a roller (using a fiber roller), allowed to dry for 2 hours, and a reddish coating was formed, which was then used.

[0078] For the base 4, a primer (black) was applied to the base material (slate board) at a rate of 150 g / m 2 The paint was applied to the entire surface with a roller (using a fiber roller), and allowed to dry for 2 hours to form a black coating which was then used.

[0079] Example 1 For the above substrate 1, a coating material A diluted 30% with water was applied as the first coating material at an amount of 50 g / m 2 The entire surface was coated with a roller (a fiber roller was used) (step [1-1]), and after it became non-fluid (dry to the touch 5 minutes after application), the trowel shown in Figure 5 was used to move the trowel in a circular motion as shown in Figure 7 to level the coating surface, and the coating was left to harden for 2 hours to form the first coating (step [1-2]). Next, a second coating material, which was made by diluting coating material B by 10% with water, was applied to the first coating at a rate of 150 g / m. 2 Immediately after coating the entire surface with a roller (using a fiber roller) (step [2-1]), the trowel shown in Figure 5 was used to apply a pattern by moving the trowel in a circular motion as shown in Figure 7. This process was continued even after coating material B became non-fluid, to apply the pattern, and the coating was then cured for 24 hours or more to form a second coating (step [2-2]). In the [1-2] step, the work could be done smoothly and efficiently with a trowel, and the coating surface could be easily leveled and flattened. Furthermore, in the [2] step ([2-1] step, [2-2] step), the work could be done smoothly and efficiently with a trowel, and the formed coating had a velvet-like, shiny pattern and excellent aesthetics.

[0080] Example 2 For the above substrate 1, coating material B diluted 30% with water was applied as the first coating material at an amount of 50 g / m 2 The entire surface was coated with a roller (a fiber roller was used) (step [1-1]), and after it became non-fluid (dry to the touch 5 minutes after application), the trowel shown in Figure 5 was used to move the trowel in a circular motion as shown in Figure 7 to level the coating surface, and the coating was left to harden for 2 hours to form the first coating (step [1-2]). Next, a second coating material, which was made by diluting coating material B by 10% with water, was applied to the first coating at a rate of 150 g / m. 2Immediately after coating the entire surface with a roller (using a fiber roller) (step [2-1]), the trowel shown in Figure 5 was used to apply a pattern as shown in Figure 7, using a trowel to draw a circle. This process was continued even after coating material B became non-flowable, and at this time the trowel was moved in a figure-eight pattern as shown in Figure 8 to apply a pattern. This was then cured for 24 hours or more to form a second coating (step [2-2]). In the [1-2] step, the work could be done smoothly and efficiently with a trowel, and the coating surface could be easily leveled and flattened. Furthermore, in the [2] step ([2-1] step, [2-2] step), the work could be done smoothly and efficiently with a trowel, and the formed coating was a coating with an excellent aesthetic appearance, featuring a luxurious, velvet-like, shiny pattern.

[0081] Example 3 For the above substrate 1, coating material B diluted 30% with water was applied as the first coating material at an amount of 50 g / m 2 The entire surface was coated with a roller (using a fiber roller) (step [1-1]), and after it became non-fluid (dry to the touch 5 minutes after application), the trowel shown in Figure 2 was used to move the trowel in a circular motion as shown in Figure 7 to level the coating surface, and the coating was left to harden for 2 hours to form the first coating (step [1-2]). Next, a second coating material, which was made by diluting coating material B by 10% with water, was applied to the first coating at a rate of 150 g / m. 2 Immediately after coating the entire surface with a roller (using a fiber roller) (step [2-1]), the trowel shown in Figure 2 was used to apply a pattern as shown in Figure 7, using a trowel to draw a circle. This process was continued even after coating material B became non-flowable, and at this time the trowel was moved in a figure-eight pattern as shown in Figure 8 to apply a pattern. This was then cured for 24 hours or more to form a second coating (step [2-2]). In the [1-2] step, the work could be done smoothly and efficiently with a trowel, and the coating surface could be easily leveled and flattened. Furthermore, in the [2] step ([2-1] step, [2-2] step), the work could be done smoothly and efficiently with a trowel, and the formed coating was a coating with an excellent aesthetic appearance, featuring a luxurious, velvet-like, shiny pattern.

[0082] Example 4 A coating was formed in the same manner as in Example 1, except that substrate 1 was replaced with substrate 2, coating material C was used as the first coating material, and coating material D was used as the second coating material. In the [1-2] step, the work could be done smoothly and efficiently with a trowel, and the coating surface could be easily leveled and flattened. Furthermore, in the [2] step ([2-1] step, [2-2] step), the work could be done smoothly and efficiently with a trowel, and the formed coating had a velvet-like, shiny pattern and excellent aesthetics.

[0083] Example 5 A coating was formed in the same manner as in Example 1, except that substrate 1 was replaced with substrate 3, coating material E was used as the first coating material, and coating material F was used as the second coating material. In the [1-2] step, the work could be done smoothly and efficiently with a trowel, and the coating surface could be easily leveled and flattened. Furthermore, in the [2] step ([2-1] step, [2-2] step), the work could be done smoothly and efficiently with a trowel, and the formed coating had a velvet-like, shiny pattern and excellent aesthetics.

[0084] Example 6 A coating was formed in the same manner as in Example 1, except that Coating Material G was used as the second coating material. In the [1-2] step, the work could be done smoothly and efficiently with a trowel, and the coating surface could be easily leveled and flattened. Furthermore, in the [2] step ([2-1] step, [2-2] step), the work could be done smoothly and efficiently with a trowel, and the formed coating had a velvet-like, shiny pattern and excellent aesthetics.

[0085] Example 7 A coating was formed in the same manner as in Example 1, except that Coating Material H was used as the second coating material. In the [1-2] step, the work could be done smoothly and efficiently with a trowel, and the coating surface could be easily leveled and flattened. Furthermore, in the [2] step ([2-1] step, [2-2] step), the work could be done smoothly and efficiently with a trowel, and the formed coating had a velvet-like, shiny pattern and excellent aesthetics. Example 8 A coating was formed in the same manner as in Example 1, except that Coating Material I was used as the second coating material. In the [1-2] step, the work could be done smoothly and efficiently with a trowel, and the coating surface could be easily leveled and flattened. Furthermore, in the [2] step ([2-1] step, [2-2] step), the work could be done smoothly and efficiently with a trowel, and the formed coating had a velvet-like, shiny pattern and excellent aesthetics.

[0086] Example 9 A coating was formed in the same manner as in Example 1, except that Coating Material J was used as the first coating material. In the [1-2] step, the work could be done smoothly with a trowel, and the coating surface could be easily leveled. Furthermore, in the [2] step ([2-1] step, [2-2] step), the work could be done smoothly and efficiently with a trowel, and the formed coating had a beautiful appearance with a velvet-like, shiny pattern.

[0087] Example 10 A coating was formed in the same manner as in Example 1, except that substrate 1 was replaced with substrate 4, coating material K was used as the first coating material, and coating material L was used as the second coating material. In the [1-2] step, the work could be done smoothly and efficiently with a trowel, and the coating surface could be easily leveled and flattened. Furthermore, in the [2] step ([2-1] step, [2-2] step), the work could be done smoothly and efficiently with a trowel, and the formed coating had a velvet-like, shiny pattern and excellent aesthetics.

[0088] Example 11 [2-2] A coating was formed in the same manner as in Example 1, except that a plastering trowel (trowel tip: triangular, trowel belly: flat, trowel material: metal) was used as the trowel used in step 2-2. In the [1-2] step, the work could be done smoothly and efficiently with a trowel, and the coating surface could be easily leveled and flattened. Furthermore, in the [2] step ([2-1] step, [2-2] step), the work could be done smoothly with a trowel, and the formed coating had a beautiful, shiny pattern.

[0089] Example 12 For the above substrate 1, a coating material A diluted 30% with water was applied as the first coating material at an amount of 50 g / m 2 The entire surface was coated with a roller (a fiber roller was used) (step [1-1]), and after it became non-fluid (dry to the touch 5 minutes after application), the trowel shown in Figure 5 was used to move the trowel in a circular motion as shown in Figure 7 to level the coating surface, and the coating was left to harden for 2 hours to form the first coating (step [1-2]). Next, a second coating material, which was made by diluting coating material B by 10% with water, was applied to the first coating at a rate of 150 g / m. 2 The entire surface was then coated with a roller (using a fiber roller) and allowed to harden for more than 24 hours to form a second coating (step [2]). In the [1-2] step, the trowel could be used smoothly and efficiently, and the coating surface could be easily leveled and flattened. The resulting coating had a beautiful, shiny pattern.

[0090] (Comparative Example 1) For the above substrate 1, a coating material A diluted 30% with water was applied as the first coating material at an amount of 50 g / m 2 The entire surface was roller coated (using a fiber roller) (step [1-1]), and the mixture was cured for 2 hours to form a first coating. Next, a second coating material, which was made by diluting coating material B by 10% with water, was applied to the first coating at a rate of 150 g / m. 2 Immediately after coating the entire surface with a roller (using a fiber roller), the trowel shown in Figure 5 was used to apply a pattern by moving the trowel in a circular motion as shown in Figure 7. This process was continued even after coating material B had become non-fluid, to apply the pattern, and the coating was then cured for 24 hours or more to form a second coating (process [2]). In Comparative Example 1, the [1-2] step was not carried out, and the formed coating had noticeable unevenness in the base due to the primer and roller marks on the first coating, and the desired glossy pattern was not obtained.

Claims

1. A coating forming method, The method includes a step [1] of applying a first coating material to a substrate to form a first coating; The above step [1] is [1-1] step of applying a first coating material; and [1-2] a step of leveling the coating surface with a trowel after the first coating material has become non-flowable and hardening the material to form a first coating; The trowel comprises a trowel plate and a handle; A coating forming method characterized in that the bottom surface and / or edge portion of the mortarboard has a curved shape.

2. 2. The method for forming a coating according to claim 1, wherein in the step [1-2], the surface of the coating is leveled with a trowel so that the bottom edge of the trowel plate does not come into contact with the surface of the coating.

3. 2. The coating method according to claim 1, wherein the first coating material contains a resin component and powder particles, and the powder particles contain a luster pigment.

4. 2. The method for forming a coating according to claim 1, further comprising the step [2] of applying a second coating material to the first coating to form a second coating.

5. 5. The coating method according to claim 4, wherein the second coating material contains a resin component and powder particles, and the powder particles contain a luster pigment.

6. 5. The coating forming method according to claim 4, wherein the step [2] includes a step of applying a second coating material to impart a pattern.

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