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 an undercoating material onto a substrate, forming a base film, then coating a first coating material onto the base film, 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, a contrast ratio of the undercoating material is 80% or more, and the first coating material contains a resin component and a granular material, and a brilliant pigment as the granular material.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, metal (metallic), pearl, leather, ceramic (glaze), and antique finishes. In particular, decorative coatings with metal (metallic) and pearl finishes containing lustrous pigments such as aluminum pigments and mica pigments are used in buildings with high design quality.

[0003] However, the finish of a coating film containing a luster 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 the desired luster may not be achieved. For example, Patent Document 1 describes applying an enamel paint to form a primer coating before the metallic coating film formation process to prevent unevenness. Also, Patent Document 2 describes applying multiple coats of primer to the base layer and then applying the metallic paint. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Application Publication No. 2017-087144 [Patent Document 2] Japanese Patent Application Laid-Open No. 2001-259514 Summary of the Invention [Problem to be solved by the invention]

[0005] However, simply applying an enamel paint, as in Patent Document 1, may result in a poor finish of the metallic paint film because a primer film is formed along the irregularities of the structure surface. On the other hand, applying multiple coats of primer, as in Patent Document 2, is time-consuming and inefficient. [Means for solving the problem]

[0006] In order to solve these problems, the present inventors discovered a coating formation method including specific steps, and completed the present invention.

[0007] That is, the present invention has the following features. 1. A coating forming method comprising: After applying a primer to the substrate to form a base coat, [1] step of applying a first coating material to the base coating 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 hiding rate of the above primer is 80% or more, The coating forming method is characterized in that the first coating material contains a resin component and powder or granular material, and the powder or granular material contains a glittering pigment. 2. The trowel has a trowel plate and a handle; 1. The method for forming a coating according to 1, wherein the bottom surface and / or edge of the mortarboard is curved. 3. A step [2] of applying a second coating material to the first coating to form a second coating; 1. The coating forming method according to 1, wherein the second 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 3., wherein the step [2] includes a step of applying a second coating material to impart a pattern. [Effects of the Invention]

[0008] By carrying out the coating forming method of the present invention, it is possible to efficiently flatten the surface of a substrate and also to form a shiny coating that is excellent in finish and aesthetic appearance. [Brief explanation of the drawings]

[0009] [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 using the trowel shown in FIG. 1 or FIG. [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]

[0010] 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

[0011] Hereinafter, an embodiment of the present invention will be described.

[0012] The present invention provides a coating formation method, After applying a primer to the substrate to form a base coat, [1] step of applying a first coating material to the base coating 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 hiding rate of the above primer is 80% or more, The first coating material contains a resin component and powder or granular material, and the powder or granular material contains a glitter pigment.

[0013] The present invention can efficiently flatten the surface of a substrate and form a first coating film with a lustrous finish that is excellent in finish and aesthetics. When a coating material containing a lustrous pigment, such as the first coating material, is used, the finish is easily affected by the base, and in some cases, the finish may pick up the unevenness of the base, resulting in unevenness and preventing the desired design from being achieved. In contrast, in the present invention, after applying a primer to the substrate to form a base coating, step [1] involves applying a first coating material containing a glittering pigment, and after the first coating material has reached a non-flowing state, smoothing the coating surface with a trowel and allowing it to harden. This makes it possible to efficiently flatten the substrate surface and form a glittering first coating.

[0014] In the present invention, before the step [1], a primer is applied to the substrate to form a base coating [P] step. In the above step [P], it is preferable that the primer is applied to the entire surface of the substrate.

[0015] The amount of primer to be applied may be set appropriately taking into consideration the type and condition of the substrate, the finish, etc., but it is preferably 500 g / m 2 or less, more preferably 5 to 450 g / m2 (More preferably 10 to 400 g / m 2 , particularly preferably 15 to 350 g / m 2 The amount of the primer applied is preferably 2 to 300 g / m2 in terms of solid content. 2 (More preferably 3 to 280 g / m 2 , and more preferably 5 to 250 g / m 2 ) When applying the primer, it can be diluted with a dilution solvent (for example, water, etc.), and in this case, the amount applied is the amount of primer applied after dilution. When the amount of primer applied satisfies the above range, the effects of the present invention can be fully obtained. In the present invention, "a to b" is synonymous with "a or more and b or less."

[0016] Examples of application tools for applying the primer include sprays, rollers, brushes (including paintbrushes), etc. Among these, examples of rollers include fibrous rollers and porous (sponge) rollers.

[0017] In the above step [P], a primer is applied and cured to form a base coating, and then the next step is the above step [1]. 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 may be preferably carried out at room temperature (5 to 40°C).

[0018] The above-mentioned [1] step includes a [1-1] step of applying a first coating material; The method is characterized by including a step [1-2] in which, after the first coating material has become non-flowable, the coating surface is leveled with a trowel and hardened to form the first coating.

[0019] In the above step [1-1], the first coating material is preferably applied to the entire surface of the base coating. The amount of the first coating material to be applied may be determined appropriately taking into consideration the type and condition of the substrate and the undercoat, the finish, etc., but is preferably 300 g / m 2 or less, more preferably 5 to 200 g / m2 (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 amount of the first coating material applied is within the above range, the effects of the present invention can be sufficiently obtained.

[0020] 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.

[0021] 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).

[0022] 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.

[0023] The trowel used in the step [1-2] is not particularly limited, and any known trowel equipped with at least a trowel plate and a handle can be used. 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.

[0024] 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). Furthermore, the bottom surface of the mortarboard (the surface that comes into contact with the coating) may be either planar (flat plate-like) or curved.

[0025] 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.

[0026] 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.

[0027] 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] . In the present invention, it is preferable that the bottom edge (11b in Fig. 1) of the mortarboard

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

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

[0028] 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.

[0029] 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.

[0030] 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] . In the present invention, it is preferable that the bottom surface [11a] of the mortarboard

[11] has a curved shape (convex curved shape) as shown in Figures 4 and 5 (b) and (c). Also, it is preferable that the edge (outer peripheral end) [Figures 4 and 5: 11b] of the mortarboard 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 as shown in Figures 4 and 5 (b) and (c).

[0031] 4 and 5, when the bottom surface of the mortarboard has a convex curved shape, the edge (outer peripheral edge) of the mortarboard is less likely to come into contact with the coating surface, which reduces 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 has a curved shape, the edge (outer peripheral edge) of the mortarboard is even less likely to come into contact with the coating surface, which makes it easier and more efficient to flatten the first coating material.

[0032] 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).

[0033] 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.

[0034] Furthermore, when smoothing the surface of the first coating with the trowel in step [1-2], it is preferable to move the trowel in a circular motion, 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 unevenness resulting from the base, and also makes it possible to impart a lustrous pattern because the luster pigment is oriented in the direction of the trowel movement, resulting in the formation of a first coating with excellent aesthetics. Furthermore, even when the amount of the first coating material applied is relatively small, as in the above-mentioned step [1-1] of the present invention, the lustrous pigment is oriented according to the direction of movement of the trowel, so that a calm lustrous pattern can be imparted.

[0035] In the present invention, after the first coating material has been flattened and cured to form the first coating as described above, if further design features are desired, 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 are preferably carried out at room temperature (5 to 40°C).

[0036] 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 contains a resin component and powder or granules, and the powder or granules preferably contain a lustrous pigment. It may be applied according to the desired design; for example, it may be applied to the entire surface of the first coating film or partially (discontinuously).

[0037] 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.

[0038] 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.

[0039] 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.

[0040] 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.

[0041] 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 impart a desired lustrous pattern and flatten the second coating, and the overlapping of the lustrous patterns of the first and second coatings results in a highly lustrous and aesthetically pleasing finish.

[0042] 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 makes it possible to flatten the second coating, and the luster pigment is oriented according to the direction of trowel movement, so that it is possible to impart a luster pattern such as a velvet or suede look, resulting in a finish with even greater aesthetic appeal.

[0043] Each constituent material is shown below. <Base material> The substrate is not particularly limited, but mainly includes materials that constitute the wall surfaces of buildings, civil engineering structures, 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 substrate in the present invention may be one that has been subjected to some kind of surface treatment, or may have a coating film already formed thereon or may have wallpaper attached thereto.

[0044] 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 substrate. In the present invention, the unevenness of the substrate includes, for example, various uneven patterns and irregularities formed on the surface of the substrate, unevenness on the coating surface formed by an existing paint film, paint marks (roller marks), etc.

[0045] <Undercoat material> The primer material may contain a resin component and powder or granules.

[0046] 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.

[0047] 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.

[0048] 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.

[0049] 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.

[0050] 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.

[0051] 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.

[0052] 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.

[0053] In the primer material of the present invention, it is preferable that the powder contains a glittering pigment. The glittering pigment has a scale-like shape, which is advantageous for smoothing unevenness and irregularities in the substrate, thereby improving the workability of step [1]. Although the mechanism of this action is not particularly limited, by including a glittering pigment in the base coating, the workability of the trowel in step [1] can be improved, and a smooth first coating can be efficiently formed.

[0054] 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."

[0055] The primer of the present invention can also contain one or more powders selected from color pigments and extender pigments, which can adjust the viscosity of the primer and impart desired coating properties (adhesion, strength, hiding power, etc.) to the base coat.

[0056] The content of the powder particles in the primer material is preferably 10 to 500 parts by mass (more preferably 30 to 450 parts by mass, and even more preferably 50 to 400 parts by mass) per 100 parts by mass of the solid content of the resin component. In addition, when the primer contains a luminous pigment as a powder or granule, the content of the luminous pigment is preferably 10 to 80% by mass (more preferably 15 to 70% by mass, even more preferably 20 to 60% by mass) in the total amount of the granule. In such cases, the above effects can be further enhanced.

[0057] Furthermore, the primer material contains a color pigment as a powder or granule, so that the primer film can be set to a desired color tone. The content of the color pigment in the primer material can be appropriately set according to the desired color tone. In the present invention, it is preferable that titanium oxide is contained as the color pigment. The content of titanium oxide is preferably 10 to 80 mass% (more preferably 15 to 75 mass%, even more preferably 20 to 70 mass%, particularly preferably 25 to 65 mass%) of the total amount of powder or granule.

[0058] In the present invention, the color difference (ΔE) between the primer and the first coating material is preferably 10 or less (preferably 8 or less), which allows the primer and the first coating material to be integrated, thereby improving aesthetic appearance.

[0059] The color difference (ΔE) in the present invention is a value measured using a color difference meter. Specifically, each coating material (referred to as "primer" and "first coating material") is applied to a standard white paper using a film applicator with a gap of 300 μm, and the coated surface is placed horizontally and dried for 48 hours under standard conditions (temperature 23°C, relative humidity 50%; the same applies below). The color difference (ΔE) can be calculated using the following formula from the L* value, a* value, and b* value (average values ​​of three or more measurement points) of the coating. <expression> △E={(L * 1-L * 2) 2 +(a * 1-a * 2) 2 +(b * 1-b * 2) 2} 0.5 (In the formula, L * 1, a * 1, b * 1 is the L of the primer * , a * , b * , L * 2, a * 2, b * 2 is the L of the first coating material * , a * , b * )

[0060] The hiding rate of the primer is 80% or more (more preferably 85% or more, even more preferably 90% or more, and particularly preferably 95% or more). In such cases, the substrate can be sufficiently hidden, and a coating film with excellent aesthetics can be formed. The hiding rate is calculated using the following formula after measuring the visual reflectance of the test piece obtained by applying the primer to a hiding rate test paper using a film applicator (gap 300 μm) and drying it for 24 hours under standard conditions. <expression> Concealment rate (%) = (visual reflectance of paint film on black background) / (visual reflectance of paint film on white background) x 100

[0061] <First covering material> The first coating material contains a resin component and powder or granular material, and the powder or granular material contains a glitter pigment.

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

[0063] The first coating material of the present invention contains a luster pigment, which allows the first coating material to be efficiently spread in step [1] and efficiently form a flattened coating. The mechanism of action is not particularly limited, but the luster pigment has a scaly shape, which improves trowel workability and facilitates alignment by spreading the luster pigment with a trowel in a non-fluid state, allowing for the efficient formation of a flattened coating. Furthermore, luster is imparted to the surface while flattening it, improving its aesthetic appearance.

[0064] The first coating material of the present invention can contain the above color pigment and extender pigment as powder particles in addition to the above luster pigment, thereby enabling desired color tone, luster, etc. to be achieved. The content of the color pigment in the first coating material is preferably 0.1 to 10 parts by mass (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 1 to 100 parts by mass (more preferably 3 to 80 parts by mass, and even more preferably 5 to 50 parts by mass) per 100 parts by mass of the solid content of the resin component.

[0065] 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 also works advantageously when adjusting the non-flowing state of the coating surface by adding water when smoothing the first coating surface with the trowel.

[0066] 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.

[0067] 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.

[0068] The content of the powder or granule in the first coating material is preferably 10 to 500 parts by mass (more preferably 30 to 450 parts by mass, and even more preferably 50 to 400 parts by mass) per 100 parts by mass of the solid content of the resin component.

[0069] The content of the luster pigment in the first coating material is preferably 5 to 500 parts by mass (more preferably 15 to 430 parts by mass, and even more preferably 28 to 360 parts by mass) per 100 parts by mass of the solid content of the resin component. The content of the luster pigment in the first coating material is preferably 50 to 100% by mass, more preferably 53 to 98% by mass, and even more preferably 55 to 95% by mass, based on the total amount of powder or granule. A luster pigment content within this range facilitates efficient formation of a flattened coating film and facilitates the production of a luster pattern.

[0070] The content of the powder or granules (extender pigment and coloring pigment) excluding the luster pigment in the first coating material is preferably 0 to 250 parts by mass (more preferably 5 to 200 parts by mass, and even more preferably 15 to 50 parts by mass) relative to 100 parts by mass of the solid content of the resin component, and is preferably 0 to 50% by mass (more preferably 2 to 47% by mass, and even more preferably 5 to 45% by mass) of the total amount of the powder or granules.

[0071] Furthermore, the content of the porous powder or granules in the first coating material is preferably 0 to 100 parts by mass (more preferably 2 to 80 parts by mass, and even more preferably 3 to 50 parts by mass) relative to 100 parts by mass of the solid content of the resin component, and is preferably 0 to 50% by mass (more preferably 2 to 47% by mass, and even more preferably 5 to 45% by mass) of the total amount of powder or granules. In such a case, the above-mentioned effects can be further enhanced.

[0072] 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, antialgae 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.

[0073] 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.

[0074] 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

[0075] <Second covering material> The second coating material is applied after the first coating has been formed if further design is desired, and any desired paint can be used as long as it can create a design that makes use of the lustrous pattern of the first coating. Examples of such second coating materials include clear paint, color clear paint, multicolored pattern paint, and glitter paint (metallic paint). In the present invention, it is preferable to use a second coating material that contains a resin component and powder or granules, and the powder or granules contain a luster pigment.

[0076] The resin component and powder / granules may be the same as those described for the first coating material, and the content of these components is preferably set to the same level as for the first coating material.

[0077] By using a powder containing a glittering pigment for the second coating material, the second coating can be made flat, and because the glittering pigment orients in the direction of the trowel movement, it is possible to impart a glittering pattern such as a velvet or suede look, resulting in a more aesthetically pleasing finish. This is also advantageous in terms of workability and cost.

[0078] 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 (for example, 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 higher than the solid content at the time of application of the first coating material. In such a case, a more gorgeous glittering pattern can be imparted, and a finish with excellent aesthetics can be obtained. [Example]

[0079] The following examples will be given to clarify the features of the present invention, but the present invention is not limited to these examples.

[0080] ·Undercoating material 1 White primer 1 was produced by uniformly mixing 200 parts by mass (solids: 100 parts by mass) of acrylic resin emulsion (resin component), 130 parts by mass of titanium oxide (coloring pigment), 100 parts by mass of talc [average particle diameter: 10 μm, aspect ratio: 20] (flat pigment), 20 parts by mass of diatomaceous earth [average particle diameter: 8 μm] (extender pigment), 30 parts by mass of clay [average particle diameter: 3 μm, aspect ratio: 20] (flat pigment) and 60 parts by mass of water, as well as additives (dispersants, antifoaming agents, film-forming aids, thickeners, etc.) in a standard manner. Next, 3 parts by mass of a pale pink pigment paste containing coloring pigments (titanium oxide, yellow iron oxide, red iron oxide) was added to 100 parts by mass of the above white primer 1 and mixed to produce primer 1 with a pale pink coating (concealment rate: 98%). ·Undercoat material 2 White primer 2 was produced by uniformly mixing 200 parts by mass (solids: 100 parts by mass) of acrylic resin emulsion (resin component), 75 parts by mass of titanium oxide (coloring pigment), 200 parts by mass of heavy calcium carbonate (extender pigment), 60 parts by mass of water, and additives (dispersant, antifoaming agent, film-forming agent, thickener, etc.) using a standard method. Next, 3 parts by mass of pink pigment paste containing coloring pigments (titanium oxide, yellow iron oxide, red iron oxide) was added to 100 parts by mass of the above white primer 2 and mixed to produce primer 1 with a pink coating (concealment rate: 90%). ·Undercoating material 3 White primer 3 was produced by uniformly mixing 200 parts by mass (solids: 100 parts by mass) of acrylic resin emulsion (resin component), 6 parts by mass of titanium oxide (coloring pigment), 100 parts by mass of talc [average particle diameter: 10 μm, aspect ratio: 20] (flat pigment), 35 parts by mass of diatomaceous earth [average particle diameter: 8 μm] (extender pigment), 30 parts by mass of clay [average particle diameter: 3 μm, aspect ratio: 20] (flat pigment) and 60 parts by mass of water, as well as additives (dispersants, antifoaming agents, film-forming aids, thickeners, etc.) in accordance with a standard method. Next, 3 parts by mass of pink pigment paste containing coloring pigments (titanium oxide, yellow iron oxide, red iron oxide) was added to 100 parts by mass of the above white primer 3 and mixed to produce primer 1 with a pink coating (concealment rate: 77%). ·Undercoating material 4 Three parts by mass of yellow pigment paste containing coloring pigments (titanium oxide, yellow iron oxide, red iron oxide) was added to 100 parts by mass of the above white primer 1 and mixed to produce primer 4 with a yellow coating (concealment rate: 97%).

[0081] ·Coating material A Coating material a was produced by uniformly mixing 200 parts by mass (solids content: 100 parts by mass) of acrylic resin emulsion (resin component), 150 parts by mass of white pearl mica pigment [silver color, average particle size: 23 μm, aspect ratio: 50] (pearl pigment), 20 parts by mass of diatomaceous earth [average particle size: 23 μm] (extender pigment), 250 parts by mass of water, and additives (dispersant, antifoaming agent, film-forming aid, thickener, etc.) using a standard method. Next, 3 parts by mass of a pale pink pigment paste containing color pigments (titanium oxide, yellow iron oxide, red iron oxide) was added to 100 parts by mass of the above coating material a and mixed to produce coating material A (hiding rate: 98%) with a pale pink coating. ·Coating material B Coating material b was produced by uniformly mixing 200 parts by mass (solids content: 100 parts by mass) of acrylic resin emulsion (resin component), 150 parts by mass of gold pearl mica pigment [gold color, average particle size: 23 μm, aspect ratio: 50] (pearl pigment), 20 parts by mass of diatomaceous earth [average particle size: 23 μm] (extender pigment), 250 parts by mass of water, and additives (dispersant, antifoaming agent, film-forming aid, thickener, etc.) using a standard method. Next, 3 parts by mass of a yellow pigment paste containing color pigments (titanium oxide, yellow iron oxide, red iron oxide) was added to 100 parts by mass of the above coating material b and mixed to produce coating material B (hiding rate: 97%) with a yellow coating.

[0082] Example 1 Apply 150g / m of primer 1 (light pink) to the base material (slate board). 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 pale pink base coat. The first coating material was prepared by diluting coating material A by 30% with water and applied at a rate of 50 g / m2 to the above base coating. 2 The primer and first coating were applied to the entire surface with a roller (using a fiber roller), and once it had reached a non-flowing state (dry to the touch 5 minutes after application), the coating surface was leveled by moving the trowel in a circular motion as shown in Figure 7, and then the coating was left to cure for 2 hours to form the first coating. The primer and first coating formed a coating with a flattened, hiding effect, and also a first coating with a subdued, lustrous pattern.

[0083] Example 2 Apply 150g / m of primer 2 (light pink) to the base material (slate board). 2 The paint was then applied to the entire surface with a roller (using a fiber roller) and allowed to dry for 2 hours to form a pale pink base coat 2. The first coating material was prepared by diluting coating material A by 30% with water and applied at a rate of 50 g / m2 to the above base coating. 2 The coating was applied to the entire surface with a roller (using a fiber roller) and, once it had reached a non-flowable state (dry to the touch 5 minutes after application), the coating surface was leveled using the trowel shown in Figure 5 by moving it in a circular motion as shown in Figure 7, and the coating was allowed to cure for 2 hours to form a first coating. Although the first coating was slightly inferior to Example 1 in terms of flattening the substrate and hiding effect, it was possible to form a first coating with a subdued, glittering pattern.

[0084] Example 3 Apply 150g / m of primer 1 (light pink) to the base material (slate board). 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 pale pink base coat. The first coating material was prepared by diluting coating material A by 30% with water and applied at a rate of 50 g / m2 to the above base coating. 2 The primer and first coating were applied to the entire surface with a roller (using a fiber roller), and once it had reached a non-flowing state (dry to the touch 5 minutes after application), the coating surface was leveled by moving the trowel in a circular motion as shown in Figure 7, and then the coating was left to cure for 2 hours to form the first coating. The primer and first coating formed a coating with a flattened, hiding effect, and also a first coating with a subdued, lustrous pattern. Next, a second coating material, which was made by diluting coating material A 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 A had become non-flowable, to apply the pattern, and the coating was then cured for 24 hours or more to form a second coating. The resulting coating had a beautiful, velvety, gorgeous, and shiny pattern, with the glittering patterns of the first and second coatings combined together.

[0085] Example 4 Apply 150g / m of primer 1 (light pink) to the base material (slate board).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 pale pink base coat. The first coating material was prepared by diluting coating material A by 30% with water and applied at a rate of 50 g / m2 to the above base coating. 2 The primer and first coating were applied to the entire surface with a roller (using a fiber roller), and once it had reached a non-flowing state (dry to the touch 5 minutes after application), the coating surface was leveled by moving the trowel in a circular motion as shown in Figure 7, and then the coating was left to cure for 2 hours to form the first coating. The primer and first coating formed a coating with a flattened, hiding effect, and also a first coating with a subdued, lustrous pattern. Next, a second coating material, which was made by diluting coating material A 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 A became non-flowable, and at this time the trowel was moved in a figure-eight motion as shown in Figure 8 to apply a pattern, which was then cured for 24 hours or more to form a second coating. The resulting coating had a gorgeous, velvety, shiny pattern that combined the shiny patterns of the first and second coatings, resulting in a coating with excellent aesthetics.

[0086] Example 5 Apply 150g / m of primer 1 (light pink) to the base material (slate board). 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 pale pink base coat. The first coating material was prepared by diluting coating material A by 30% with water and applied at a rate of 50 g / m2 to the above base coating. 2The primer was applied to the entire surface with a roller (using a fiber roller), and once it had reached a non-flowing state (dry to the touch 5 minutes after application), the trowel shown in Figure 2 was used to smooth the coating surface by moving it in a circular motion as shown in Figure 7, and the coating was left to cure for 2 hours to form the first coating. The primer and first coating formed a coating with a flattened, hiding effect, and also a first coating with a subdued, lustrous pattern. Next, a second coating material, which was made by diluting coating material A 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 2 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 A became non-flowable, and at this time the trowel was moved in a figure-eight motion as shown in Figure 8 to apply a pattern, which was then cured for 24 hours or more to form a second coating. The resulting coating had a gorgeous, velvety, shiny pattern that combined the shiny patterns of the first and second coatings, resulting in a coating with excellent aesthetics.

[0087] Example 6 Primer 4 (yellow) was applied to the base material (slate board) at a rate of 150 g / m 2 The paint was then applied to the entire surface with a roller (using a fiber roller) and allowed to dry for 2 hours to form a yellowish base coat. The first coating material was made by diluting coating material B by 30% with water and applying it at a rate of 50 g / m2 to the above base coating. 2 The primer and first coating were applied to the entire surface with a roller (using a fiber roller), and once it had reached a non-flowing state (dry to the touch 5 minutes after application), the coating surface was leveled by moving the trowel in a circular motion as shown in Figure 7, and then the coating was left to cure for 2 hours to form the first coating. The primer and first coating formed a coating with a flattened, hiding effect, and also a first coating with a subdued, lustrous pattern.

[0088] (Comparative Example 1) Apply 150g / m of primer 1 (light pink) to the base material (slate board). 2The paint was applied to the entire surface with a roller (using a fiber roller) and allowed to dry for 2 hours to form a pale pink base coat. The first coating material was prepared by diluting coating material A by 30% with water and applied at a rate of 50 g / m2 to the above base coating. 2 The entire surface was roller coated (using a fiber roller) and allowed to harden for 2 hours to form the first coating. The formed coating had noticeable unevenness in the base caused by the primer and roller marks of the first coating, and the desired lustrous pattern was not obtained.

[0089] (Comparative Example 2) Apply 150g / m of primer 3 (light pink) to the base material (slate board). 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 pale pink base coat. The first coating material was prepared by diluting coating material A by 30% with water and applied at a rate of 50 g / m2 to the above base coating. 2 The entire surface was roller coated (using a fiber roller) and allowed to harden for 2 hours to form the first coating. The formed coating had noticeable unevenness in the base due to roller marks from the primer and first coating, poor hiding power for the substrate, and a lack of brilliance.

[0090] (Comparative Example 3) Apply 150g / m of primer 1 (light pink) to the base material (slate board). 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 pale pink base coat. The first coating material was prepared by diluting coating material A by 30% with water and applied at a rate of 50 g / m2 to the above base coating. 2 The entire surface was roller coated (using a fiber roller) and allowed to harden for 2 hours to form the first coating. Next, a second coating material, which was made by diluting coating material A 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), a pattern was created using the trowel shown in Figure 5 by moving the trowel in a circular motion as shown in Figure 4. This process was continued even after Coating Material B had become non-flowable, creating a pattern, and the coating was then cured for 24 hours or more to form a second coating. The formed coating had noticeable unevenness in the base caused by the primer and roller marks of the first coating, and the desired lustrous pattern was not obtained.

Claims

1. A coating forming method, After applying a primer to the substrate to form a base coat, The method includes a step [1] of applying a first coating material to the base coating 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 hiding rate of the primer is 80% or more, The coating film forming method is characterized in that the first coating material contains a resin component and powder or granular material, and the powder or granular material contains a glitter pigment.

2. The trowel comprises a trowel plate and a handle; 2. The method for forming a coating according to claim 1, wherein the bottom surface and / or edge of the mortarboard is curved.

3. [2] step of applying a second coating material to the first coating to form a second coating; 2. The coating method according to claim 1, wherein the second coating material contains a resin component and powder particles, and the powder particles contain a luster pigment.

4. 4. The coating forming method according to claim 3, wherein the step [2] includes a step of applying a second coating material to impart a pattern.

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