Method for forming a coating film on a metal powder surface

Abstract

Provided are a method for forming a metal powder-exposed coating film that can provide a favorable metallic texture, a member with a metal powder-exposed coating film, and a metal powder-exposed coating film. [Solution] The method for forming a metal powder-exposed coating film includes a coating step of applying a metal powder-containing paint to a surface to be coated (11), a metal powder precipitation step of drying the metal powder-containing paint after the coating step to form a metal powder-containing coating film on the surface to be coated (11) and precipitating the metal powder (21) contained in the applied metal powder-containing paint, and a metal powder layer formation step of polishing the surface of the metal powder-containing coating film after the metal powder precipitation step to expose the metal powder (21) within the metal powder-containing coating film, thereby forming a metal powder layer (30) as the outermost layer. Furthermore, a member with a metal powder-exposed coating film and a metal powder-exposed coating film (50) produced using this method can achieve a desirable metallic texture.

Description

[Technical Field]

[0001] The present invention relates to a method for forming a metal powder-exposed coating film, a member with a metal powder-exposed coating film, and a metal powder-exposed coating film. [Background technology]

[0002] When applied to a surface, paint containing metal powder imparts a unique metallic luster to the surface, creating a beautiful appearance. In addition, paint containing metal powder also has the advantage of being excellent in weather resistance.

[0003] In paints containing such metal powders, the metal powder components are generally used in a dispersed state in the liquid component so that they do not settle (see, for example, Patent Document 1). That is, dispersants are added to ensure that the metal powder is well dispersed in the paint, and curing agents are often used so that the paint hardens before the metal powder components settle after application. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Application Laid-Open No. 2001-31901 Summary of the Invention [Problem to be solved by the invention]

[0005] However, the inventors have succeeded in forming a coating film with a strong metallic luster and rich design potential that has never been seen before by deliberately precipitating the metal powder in the paint, thereby increasing the density of the metal powder, forming a so-called metal powder layer within the paint film, and exposing this metal powder layer as the outermost layer.

[0006] Therefore, an object of the present invention is to provide a method for forming a metallic powder-exposed coating film that can provide a desirable metallic texture, a member with a metallic powder-exposed coating film, and a metallic powder-exposed coating film. [Means for solving the problem]

[0007] The present invention is a method for forming a metal powder-exposed coating film, comprising: a coating step of applying a metal powder-containing paint to a surface to be coated; a metal powder precipitation step of drying the metal powder-containing paint after the coating step to form a metal powder-containing coating film on the surface to be coated and precipitating the metal powder contained in the applied metal powder-containing paint; and a metal powder layer formation step of polishing the surface of the metal powder-containing coating film after the metal powder precipitation step to expose the metal powder in the metal powder-containing coating film, thereby forming a metal powder layer as the outermost layer. Also, there is provided a member with a metal powder-exposed coating film, which comprises a member to be painted including a surface to be painted, and a metal powder-exposed coating film formed on the surface to be painted, characterized in that the metal powder-exposed coating film is formed by applying a metal powder-containing paint to the surface to be painted, drying the metal powder-containing paint to form a metal powder-containing coating film on the surface to be painted, causing the metal powder contained in the applied metal powder-containing paint to settle, and polishing the surface of the metal powder-containing coating film to expose the metal powder in the metal powder-containing coating film, thereby forming a metal powder layer as the outermost layer. The present invention also provides a metal powder-exposed coating film formed on a surface of a member to be painted, the surface being characterized in that a metal powder-containing paint is applied to the surface to be painted, the metal powder-containing paint dries to form a metal powder-containing coating film on the surface to be painted, and the metal powder contained in the applied metal powder-containing paint precipitates, the surface of the metal powder-containing coating film is polished to expose the metal powder in the metal powder-containing coating film, thereby forming a metal powder layer as the outermost layer.

[0008] In this configuration, the metal powder is deliberately precipitated to form a metal powder layer, which adequately protects the surface to be painted, and then the metal powder layer is exposed to the surface, resulting in a strong metallic luster.

[0009] In the above invention, the metal powder-containing paint may contain unsaturated polyester, styrene, a thixotropy adjusting agent, a surfactant, and a curing agent. The member with a metal powder-exposed coating film comprises a member to be coated that includes a surface to be coated, and a metal powder-exposed coating film formed on the surface to be coated, and the metal powder-exposed coating film is characterized in that when a metal powder-containing paint is applied to the surface to be coated to form a metal powder-exposed coating film, the metal powder contained in the metal powder-exposed paint is precipitated and the surface of the metal powder-exposed coating film is polished to expose the metal powder in the metal powder-exposed coating film, forming a metal powder layer on the outermost layer. When a metal powder-containing coating film is formed on the surface to be coated, the metal powder contained in the metal powder-containing paint is precipitated, and the surface of the metal powder-containing coating film is polished to expose the metal powder in the metal powder-containing coating film, thereby forming a metal powder layer as the outermost layer. The metal powder may be a powder of a predetermined metal material. The metal powder may also contain powders of two or more metals. [Effects of the Invention]

[0010] The present invention has an excellent effect of providing a desirable metallic texture that has not been available before. [Brief explanation of the drawings]

[0011] [Figure 1] 1 is an explanatory diagram showing a state in which a metal powder-containing paint is applied to a member to be painted according to an embodiment of the present invention. [Figure 2] FIG. 2 is an explanatory view showing the state in which a metal powder layer is formed by drying a metal powder-containing paint according to an embodiment. [Figure 3] FIG. 2 is an explanatory view showing a state in which a metal powder layer according to an embodiment is exposed. DETAILED DESCRIPTION OF THE INVENTION

[0012] Hereinafter, examples embodying the method for forming a metal powder-exposed coating film, the member with a metal powder-exposed coating film, and the metal powder-exposed coating film according to the present invention will be described in detail. Note that the present invention is not limited to the examples shown below, and appropriate design modifications are possible.

[0013] [Formation of metal powder surface coating film] The method for forming the metal powder-exposed coating film will be explained below in order.

[0014] [Coating process] As shown in Figure 1, a metal powder-containing paint 20 is applied to a surface 11 of a member 10 to be painted, which is a building material such as an interior or exterior material. At this time, metal powders 21 in the metal powder-containing paint 20 are dispersed and present randomly within the metal powder-containing paint 20.

[0015] [Metal powder precipitation process] In the coating process, the metal powder-containing paint 20 applied to the surface 11 to be coated is left to dry, and as shown in Figure 2, the metal powder 21 settles to form a metal powder layer 30 adjacent to the surface 11 to be coated. At this time, the outermost surface layer 40 becomes a resin layer containing almost no metal powder.

[0016] [Metal powder layer formation process] Next, the surface layer 40 is polished to expose the metal powder layer 30 as shown in FIG. 3, forming a metal powder-exposed coating film 50 and turning the coating target member 10 into a member 60 with a metal powder-exposed coating film.

[0017] Here, the following examples are proposed as components of the metal powder-containing paint.

[0018] [Unsaturated polyester] The unsaturated polyester is the main liquid component of the metal powder-containing paint, and is preferably added in an amount of 80 to 70 parts by mass.

[0019] 〔styrene〕 Styrene is added to the unsaturated polyester to promote curing and adjust viscosity, and is preferably added in an amount of 20 to 30 parts by mass.

[0020] [Curing agent] The curing agent is used to cure the liquid unsaturated polyester. The curing agent is preferably added in an amount of 0.5 to 3 parts by mass. In some cases, cobalt naphthenate or the like may be added as a curing accelerator.

[0021] [Surfactant] The addition of a surfactant provides a favorable separation effect between the liquid components and the metal powder in the metal powder-containing paint after application. Examples of surfactants include anionic surfactants, cationic surfactants, amphoteric surfactants, and nonionic surfactants. Preferably, the surfactant is added in an amount of 0.1 to 2 parts by mass. If the amount is less than 0.1 parts by mass, the surfactant's favorable separation effect cannot be obtained. If the amount is more than 2 parts by mass, the surfactant's effect is saturated within the paint components, and the excess surfactant is wasted.

[0022] [Thixotropy improver] The addition of a thixotropy modifier provides a favorable dispersion effect for the metal powder in the liquid, such as unsaturated polyester, in the coating material before application. Examples of thixotropy modifiers include polyhydroxycarboxylic acid amides and polyhydroxycarboxylic acid esters. The thixotropy modifier is preferably added in an amount of 0.1 to 3 parts by mass. If the amount is less than 0.1 part by mass, the thixotropy modifier does not provide a favorable dispersion effect. If the amount is more than 3 parts by mass, the effect of the thixotropy modifier is saturated within the coating material, and the excess amount of thixotropy modifier is wasted.

[0023] [Metal powder] The metal powder is not particularly limited, and any metal type can be used as long as it is a powderable metal, such as iron, copper, brass, bronze, aluminum, stainless steel, zinc, or tin. Furthermore, by blending multiple types of metal powder, metallic properties resembling an alloy can be achieved in design. Furthermore, the density of the resulting metal powder-exposed coating film can be freely designed. For example, it is preferable to add 100 to 300 parts by mass of metal powder.

[0024] Next, the method for preparing the paint will be described. The viscosity was measured using a viscosity cup NK-2 (manufactured by Anest Iwata Corporation) (unit: seconds).

[0025] A metal powder-containing paint was prepared as follows.

[0026] [Adjustment method] A surfactant, a styrene monomer, and a thixotropy modifier are added to an unsaturated polyester binder and stirred, and then metal powder is added and further stirred.

[0027] Metal powder is added and stirred, and the viscosity is measured.

[0028] The prepared metal powder-containing paint is applied to the surface to be painted.

[0029] Leave the paint at 60°C for 30 to 60 minutes, then check for hardening. Then, wipe the painted surface with thinner until the paint film loses its luster. Then, sand the painted surface (sanding in stages from #220 to #5000 grit), and check the appearance.

[0030] However, the present invention is not limited to the above-described embodiments, and can be modified as appropriate within the scope of the gist of the present invention. [Explanation of symbols]

[0031] 10 Painting target materials 11 Painting surface 20 Paint containing metal powder 21 Metal powder 30 Metal powder layer 40 Surface layer 50 Metal powder exposed coating film 60 Metal powder surface coated parts

Claims

1. a coating process of applying a metal powder-containing paint to a surface to be coated; a metal powder precipitation step of drying the metal powder-containing paint after the painting step to form a metal powder-containing coating film on the surface to be painted and precipitating the metal powder contained in the applied metal powder-containing paint; a metal powder layer forming step of polishing the surface of the metal powder-containing coating film after the metal powder precipitating step to expose the metal powder in the metal powder-containing coating film, thereby forming a metal powder layer as an outermost layer; A method for forming a metal powder-exposed coating film, comprising:

2. A member with a metal powder-exposed coating film, comprising: a member to be coated including a surface to be coated; and a metal powder-exposed coating film formed on the surface to be coated, The metal powder surface coating film is A metal powder-containing paint is applied to the surface to be painted, The metal powder-containing paint dries to form a metal powder-containing coating film on the surface to be painted, and the metal powder contained in the applied metal powder-containing paint precipitates, The surface of the metal powder-containing coating film is polished to expose the metal powder in the metal powder-containing coating film, thereby forming a metal powder layer as the outermost layer. A member with a metal powder-exposed coating film, characterized in that:

3. A metal powder-exposed coating film formed on a surface of a member to be coated, the surface being a target surface of the member to be coated, A metal powder-containing paint is applied to the surface to be painted, The metal powder-containing paint dries to form a metal powder-containing coating film on the surface to be painted, and the metal powder contained in the applied metal powder-containing paint precipitates, The surface of the metal powder-containing coating film is polished to expose the metal powder in the metal powder-containing coating film, thereby forming a metal powder layer as the outermost layer. A metal powder-exposed coating film characterized by:

4. The metal powder is a powder of a predetermined metal material. The method for forming a metal powder-exposed coating film according to claim 1.

5. The metal powder is a powder of a predetermined metal material. The member having a metal powder-exposed coating film according to claim 2.

6. The metal powder is a powder of a predetermined metal material. The metal powder-exposed coating film according to claim 3.

7. The metal powder contains powders of two or more metals. The method for forming a metal powder-exposed coating film according to claim 1.

8. The metal powder contains powders of two or more metals. The member having a metal powder-exposed coating film according to claim 2.

9. The metal powder contains powders of two or more metals. The metal powder-exposed coating film according to claim 3.

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