Method for forming a patterned surface

Abstract

To provide a method by which a border between a joint part and a pattern part becomes neat finish, and a joint pattern having excellent beauty appearance can be formed.SOLUTION: According to this method, the following processes (1) to (5) are performed: (1) a first process in which a primer material is coated, thereby forming a primer material layer; (2) a second process in which peelable joint material is placed on a surface of the primer material layer; (3) a third process in which a middle coating material is coated onto the surface obtained in the second process, thereby forming a middle coating material layer; (4) a fourth process in which a top coating material is coated onto a surface of the middle coating material layer, thereby forming a top coating material layer; and (5) a fifth process in which the joint material is removed. A color difference between the primer coating material layer and the middle coating material layer is so made as to be less than 10.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to a method for forming a patterned surface. The present invention is applicable mainly to buildings, civil engineering structures, and the like. [Background technology]

[0002] In the coating of walls of buildings and civil engineering structures, a technique for providing joint patterns such as tile patterns is used. This technique makes it possible to form highly designed patterned surfaces.

[0003] One method for forming a joint pattern is to apply a rod-shaped or plate-shaped joint material to the base, apply a finish coat, and then remove the joint material, as described, for example, in JP-A-2-292450 and JP-A-10-266517, etc. According to the methods described in these patent documents, it is expected that a patterned surface full of design will be obtained by the contrast between the joint and pattern parts, the steps, etc. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Unexamined Patent Publication No. 2-292450 [Patent Document 2] Japanese Patent Application Publication No. 10-266517 Summary of the Invention [Problem to be solved by the invention]

[0005] However, in reality, methods such as those described in the above-mentioned patent documents may result in the coating material getting into the gap between the base and the joint material, resulting in a jagged finish at the boundary between the joint and the pattern, making it difficult to obtain a clean, aesthetically pleasing patterned surface.

[0006] The present invention has been made in consideration of such problems, and aims to provide a method for forming a joint pattern with excellent aesthetics, with a neat finish at the boundary between the joint and the pattern part. [Means for solving the problem]

[0007] In order to achieve the above-mentioned object, the inventors conducted intensive research and came up with a method of painting a primer onto a substrate, attaching a joint material, and then painting an intermediate coating material that satisfies specific conditions and a top coating material in that order, thereby completing the present invention.

[0008] That is, the present invention has the following features. 1. A method for forming a patterned surface having a joint pattern, comprising: (1) The first step is to apply a primer to the substrate to form a primer layer; (2) a second step of applying a peelable joint material to the surface of the primer layer; (3) A third step of applying an intermediate coating material to the surface obtained in the second step to form an intermediate coating material layer; (4) A fourth step of applying a topcoat material to the surface of the intermediate coating material layer to form a topcoat material layer; (5) A fifth step of removing the joint material; The purpose is to The color difference between the undercoat layer and the intermediate coat layer is less than 10. the law of nature, The undercoat material contains a resin component, a color pigment, and a powder having an average particle diameter of 1 μm or more and a refractive index of 1.3 to 1.7, The intermediate coating material contains a resin component, a color pigment, and a powder having an average particle diameter of 1 μm or more and a refractive index of 1.3 to 1.7, The weight ratio of the powder in the intermediate coating material is smaller than the weight ratio of the powder in the undercoat material. A method for forming a patterned surface. 2. The above primer is The powder and granule are mixed in an amount of 50 to 600 parts by weight per 100 parts by weight of the solid content of the resin component. 1. A method for forming a patterned surface, comprising: 3. The above intermediate coating materials are The powder and granule are mixed in an amount of 10 to 300 parts by weight per 100 parts by weight of the solid content of the resin component. 3. The method for forming a patterned surface according to 1. or 2., 4. The method for forming a patterned surface according to any one of 1. to 3., characterized in that the color difference between the undercoat layer and the topcoat layer is 10 or more. Effect of the Invention

[0009] According to the present invention, the boundary between the joint portion and the pattern portion has a neat finish, and a joint pattern with excellent aesthetic appearance can be formed. [Brief description of the drawings]

[0010] [Figure 1] FIG. 1 is a schematic diagram showing an example of the present invention. [Diagram 2] FIG. 2 is a schematic diagram showing another example of the present invention. [Explanation of symbols]

[0011] a: Base material b: Undercoat layer c: Peelable joint material d: Adhesive layer e: Intermediate coating material layer f, f1, f2: Topcoat layer g: Joint area h: Pattern part DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

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

[0013] The present invention is a method for forming a patterned surface having a joint pattern. Figure 1 is a schematic diagram showing an example of the present invention. In the present invention, the joint portion is a portion of the patterned surface that forms a linear concave portion, and the undercoat material layer b is visible in this joint portion. On the other hand, the pattern portion is a portion of the patterned surface that forms a convex portion, and the topcoat material layer f is visible in this pattern portion (Figure 1 (5)).

[0014] The present invention can be applied to, for example, the interior and exterior wall surfaces, ceilings, floors, etc. of buildings, or the surfaces of civil engineering structures. Examples of the substrate a constituting such a portion include various substrates such as concrete, mortar, fiber-mixed cement board, cement calcium silicate board, slag cement perlite board, ALC board, siding board, extrusion molding board, gypsum board, perlite board, plywood, plastic board, metal board, woodwork board, ceramic tile, etc. These substrates may be ones that have been subjected to some surface treatment (for example, cleaning treatment by applying a detergent, high-pressure washing, etc.; treatment to remove fragile parts using a sander, a skin scraper, a scraping bar, etc.; painting with a filler, a surfacer, a sealer, etc., or a base treatment by attaching a mesh, etc.), ones that have already been colored with a colored paint, etc., ones that already have a coating film formed thereon, ones with wallpaper attached, ones with a heat insulating layer laminated, etc.

[0015] As the first step, a primer is applied to the above-mentioned substrate a to form a primer layer b (Fig. 1(1)). This primer layer b appears as the joint area g in the final patterned surface. Therefore, the color tone of the primer layer b can be set to match the desired joint color.

[0016] The undercoat material may be, for example, a material containing a resin component and a color pigment. In such a undercoat material, the type and mixing ratio of the color pigment may be appropriately adjusted to set the undercoat layer b to the desired color tone.

[0017] The resin component acts as a binder. Examples of the resin component include acrylic resin, urethane resin, acrylic urethane resin, epoxy resin, vinyl chloride resin, vinyl acetate resin, acrylic silicone resin, fluororesin, polyvinyl alcohol, cellulose derivatives, and the like, or composites thereof. These can be used alone or in combination of two or more. The resin component is preferably in the form of a water-dispersible resin (resin emulsion) and / or a water-soluble resin. Of these, the water-dispersible resin can be produced by one-stage or multi-stage (two-stage, three-stage or more) emulsion polymerization method, etc.

[0018] The glass transition temperature (hereinafter also referred to as "Tg") of the resin component is preferably -30 to 50°C, more preferably -10 to 40°C. If Tg is within such a range, it is possible to ensure good performance in terms of stain resistance, crack resistance, adhesion and removability of the joint material, etc. The Tg referred to here is a value calculated by the Fox formula from the types and constituent ratios of the monomers constituting the resin component. In the present invention, "α to β" is synonymous with "α or more and β or less".

[0019] Such a resin component may have a property (crosslinking reactivity) that causes a crosslinking reaction after the coating film is formed. When the resin component has crosslinking reactivity, the water resistance, weather resistance, adhesion, etc. of the undercoat layer b can be improved, and it is also suitable in terms of joint material removability, etc. Such a resin component may be either one that causes a crosslinking reaction by itself or one that causes a crosslinking reaction by a crosslinking agent that is mixed separately. Such crosslinking reactivity can be imparted by combining reactive functional groups such as, for example, a carboxyl group and a metal ion, a carboxyl group and a carbodiimide group, a carboxyl group and an epoxy group, a carboxyl group and an aziridine group, a carboxyl group and an oxazoline group, a hydroxyl group and an isocyanate group, a carbonyl group and a hydrazide group, an epoxy group and an amino group, an aldo group and a semicarbazide group, a keto group and a semicarbazide group, and alkoxyl groups. Such a combination of reactive functional groups can be used in one or more types.

[0020] Examples of the color pigment include inorganic color pigments such as titanium oxide, zinc oxide, alumina, magnesium oxide, zirconium oxide, carbon black, ferric oxide (red oxide), yellow iron oxide, iron oxide, ultramarine, cobalt green, iron-chromium composite oxide, manganese-bismuth composite oxide, manganese-yttrium composite oxide, and manganese-iron-cobalt composite oxide; organic color pigments such as azo-based, naphthol-based, pyrazolone-based, anthraquinone-based, perylene-based, quinacridone-based, disazo-based, isoindolinone-based, benzimidazole-based, phthalocyanine-based, and quinophthalone-based; and luster pigments such as aluminum pigments and pearl pigments. One or more of these may be used.

[0021] The weight ratio of the color pigment is preferably 3 to 300 parts by weight, and more preferably 5 to 250 parts by weight, based on 100 parts by weight of the solid content of the resin component.

[0022] As the undercoat material, in addition to the resin component and the color pigment, it is more preferable to use a powder or granule (hereinafter simply referred to as "powder or granule") having an average particle diameter of 1 μm or more and a refractive index of 1.3 to 1.7. In such a undercoat material, the color pigment makes it easy to set the color tone, and the action of the powder or granule makes it possible to ensure excellent performance in the adhesion and removability of the joint material c, the finish of the joint part g, etc.

[0023] The average particle diameter of the powder or granule is 1 μm or more, preferably 2 to 100 μm, more preferably 3 to 70 μm, and further preferably 4 to 50 μm. The average particle diameter means the 50% particle diameter measured by a centrifugal sedimentation type particle size distribution measuring device. The refractive index of the powder or granule is preferably 1.3 to 1.7. The refractive index can be measured by an Abbe refractometer. In the present invention, by using a powder or granule satisfying such conditions, it is possible to improve the adhesiveness and removability of the joint material c, the finish of the joint part g, etc. while maintaining the color tone of the color pigment. In particular, by having the lower limit of the average particle diameter be equal to or more than the above value, advantageous effects can be obtained in terms of the removability of the joint material c, the finish of the joint part g, etc. When the upper limit is equal to or less than the above value, advantageous effects can be obtained in terms of the adhesiveness of the joint material c, the finish of the joint part g, etc.

[0024] Examples of powders and granules include heavy calcium carbonate, kansui stone, light calcium carbonate, white carbon, talc, kaolin, clay, china clay, diatomaceous earth, barite powder, barium sulfate, precipitated barium sulfate, silica sand, silica stone powder, quartz powder, resin powder, resin beads, etc. These can be used alone or in combination of two or more.

[0025] The weight ratio of the powder is preferably 50 to 600 parts by weight, more preferably 100 to 500 parts by weight, and even more preferably 150 to 450 parts by weight, relative to 100 parts by weight of the solid content of the resin component. By having the lower limit of the weight ratio of the powder is equal to or higher than the above value, advantageous effects can be obtained in terms of the removability of the joint material c, the finish of the joint part g, and the like, and by having the upper limit be equal to or lower than the above value, advantageous effects can be obtained in terms of the adhesion of the joint material c, the finish of the joint part g, the weather resistance, crack resistance, adhesion, and the like of the undercoat layer b.

[0026] The undercoat material may contain known additives in addition to the above components. Examples of such additives include aggregates, fibers, dispersants, emulsifiers, thickeners, film-forming assistants, leveling agents, coupling agents, wetting agents, plasticizers, antifreeze agents, pH adjusters, dryness adjusters, preservatives, antifungal agents, anti-algae agents, antibacterial agents, antifoaming agents, adsorbents, deodorizers, ultraviolet absorbers, light stabilizers, antioxidants, catalysts, crosslinking agents, etc. As long as the effects of the present invention are not significantly impaired, powders and granules other than those mentioned above (for example, powders and granules with an average particle size of less than 1 μm, etc.) may also be included. The undercoat material can be produced by appropriately mixing the above components by a conventional method.

[0027] The undercoat layer b is formed by painting such an undercoat material on the substrate a. The method of painting the undercoat material is not particularly limited, and for example, methods such as spray painting, roller painting, brush painting, and trowel painting can be adopted. In the present invention, roller painting is preferred, and it is desirable to use a porous roller as the roller. When such a roller is used, a moderate undulation is formed on the surface of the undercoat layer b, which can further improve the removability of the joint material c and the finish of the joint part g.

[0028] A porous roller, for example, has a porous layer on the outer surface of a cylindrical core material, and the cylindrical core material is hollow so that a handle with a shaft can be attached, and the roller can be used by attaching a handle shaft to the hollow.

[0029] The porous roller is preferably, for example, a roller having a sponge-like porous layer, and the porous layer is preferably one having continuous holes. The material of the porous layer is not particularly limited, but examples thereof include resins such as acrylic resin, polyurethane resin, polyester resin, polyethylene resin, and polypropylene resin, and the like, which are preferably made porous like a sponge.

[0030] The pore size of such a porous layer is preferably 0.3 to 10 mm, more preferably 0.5 to 5 mm, and further preferably 0.8 to 3 mm. The pore size of each hole may be calculated by multiplying the maximum distance from the center of gravity of each hole by 2, and the pore size of the porous layer may be calculated by the average value of 10 holes. The thickness of the porous layer is preferably 1 to 25 mm, more preferably 2 to 20 mm. The width (length) of the porous roller is preferably 50 to 300 mm. The diameter of the porous roller (the value obtained by dividing the outer circumference of the porous layer by pi) is preferably 15 to 100 mm.

[0031] When applying the undercoat material, the viscosity can be adjusted appropriately by mixing a diluent such as water. The dilution ratio is preferably 0 to 10% by weight.

[0032] The amount of the undercoat applied should be such that the substrate a is concealed by the undercoat layer b, but is preferably 0.1 to 1 kg / m 2 , more preferably 0.2 to 0.6 kg / m 2 The drying of the undercoat material may be preferably performed at room temperature (0 to 40° C.). The drying time is preferably 3 hours or more, more preferably 6 hours or more. In the present invention, it is desirable to perform the next step after drying the undercoat material layer b.

[0033] In the second step, a peelable joint material (hereinafter, "peelable joint material" is also simply referred to as "joint material") c is placed on the surface of the undercoat layer b (Figure 1 (2)). The joint material c used here may be any material that can be temporarily placed on the surface of the undercoat layer b, and for example, at least the surface that contacts the undercoat layer b may be adhesive. Figure 1 shows, as an example, a joint material having an adhesive layer d. Such a joint material can be placed by adhering it so that the adhesive layer d contacts the undercoat layer b after the undercoat layer b has dried.

[0034] Examples of materials constituting the joint material c include rubbers such as silicone rubber, fluororubber, nitrile rubber, chloroprene rubber, butyl rubber, acrylic rubber, and SBR; resins such as polyester, polyurethane, acrylic, vinyl chloride, polyethylene, polypropylene, polystyrene, and polycarbonate; and resin foams such as polyurethane foam, polyethylene foam, polypropylene foam, and polystyrene foam. These can be used alone or in combination of two or more.

[0035] The position and interval at which the joint material c is pasted may be determined according to the desired joint pattern. For example, the joint material c may be pasted at equal intervals or randomly. As the pattern, for example, a tile pattern, a brick pattern, a geometric pattern, a polka dot pattern, a striped pattern, a lattice pattern, a swirl pattern, a heraldic pattern, as well as a figure designed with animals, plants, vessels, letters, etc. are possible. In order to express these patterns, a combination of multiple linear joint materials may be used, or a flat pattern paper punched according to the desired pattern shape may be used as the joint material. Before pasting the joint material c, appropriate marking or the like may be performed to obtain the desired joint pattern. After pasting the joint material c, the surface of the joint material c may be pressed using a rubber roller, a plastic roller, a metal roller, etc., and the joint material c may be pressed against the undercoat layer b.

[0036] The width of the joint material c (the width of the portion corresponding to the joint portion g) is preferably 1 to 20 mm. The height (thickness) of the joint material c is preferably 0.1 to 10 mm, and more preferably 0.2 to 3 mm.

[0037] The joint material c may have other layers laminated thereon, so long as it has the adhesive layer d on the back side. For example, it may have an adhesive layer on the back side and a release paper on the front side. The adhesive layer may contain powder or granular material.

[0038] In the third step, the intermediate coating material is applied to the surface obtained in the second step to form the intermediate coating material layer e (Fig. 1 (3)). In this third step, the intermediate coating material is applied at least to the boundary between the joint material c and the intermediate coating material layer e (the portion where the side of the joint material c and the surface of the intermediate coating material layer e meet), and in this case, the intermediate coating material layer e may be a discontinuous coating film. However, in terms of improving work efficiency, it is desirable to apply the intermediate coating material to the entire surface of the base coating material layer b to which the joint material c is attached, that is, the entire surface including the portion to which the joint material c is attached.

[0039] The intermediate coating material is one in which the color difference between the undercoat layer b and the intermediate coating layer e is less than 10 (preferably 8 or less, more preferably 5 or less, and even more preferably 0 to 3). In the present invention, by applying an intermediate coating material that satisfies such conditions, the boundary between the joint part g and the pattern part h is finished neatly, and a joint pattern with excellent aesthetics can be formed. This effect is thought to be achieved by sealing the gap between the undercoat layer b and the joint material c with an intermediate coating material of approximately the same color as the undercoat layer b, thereby suppressing the topcoat material used in the later process from entering the gap. In the present invention, even if the composition of the undercoat material is adjusted to improve the removability of the joint material, etc., and gaps are easily generated at the contact surface between the undercoat layer b and the joint material c, a joint pattern with excellent aesthetics can be formed.

[0040] The color difference (ΔE) in the present invention is a value calculated based on the value (average value of 10 arbitrary points) of the color tone of each layer after drying measured with a color difference meter. Specifically, the color difference (ΔE eb ) is the L of each layer * Value, a * Value, b * It can be calculated from the value using the following formula 1. <Formula 1>△Eeb ={(L * e -L * b ) 2 +(a * e -a * b ) 2 +(b * e -b * b ) 2} 0.5 (In the formula, L * e , a * e , b * e are the L of intermediate coating layer e, * , a * , b * .L * b , a * b , b * b are the L of the undercoat layer b, * , a * , b * )

[0041] The intermediate coating material may be, for example, a material containing a resin component and a color pigment. In such intermediate coating materials, the type and mixing ratio of the color pigment can be appropriately adjusted to set the intermediate coating layer e to the desired color tone.

[0042] The resin components and coloring pigments in the intermediate coating material can be the same as those described for the undercoat material.

[0043] The resin component in the intermediate coating material preferably has a Tg of -30 to 50°C, more preferably -10 to 40°C. The resin component may also have cross-linking reactivity. In this case, when removing the joint material c, the joint material c can be removed by cutting it off at the width of the joint portion g, which prevents the pattern portion h from peeling off together with the joint material c, and allows the joint material c to be removed efficiently.

[0044] The weight ratio of the color pigment in the intermediate coating material is preferably 3 to 300 parts by weight, and more preferably 5 to 250 parts by weight, per 100 parts by weight of the solid content of the resin component.

[0045] The intermediate coating material can contain resin components, color pigments, and even powders similar to those used in undercoat materials. With such intermediate coating materials, it is easy to set the color tone using the color pigments, and it is also possible to ensure excellent performance in terms of the removability of the joint material c and the finish of the joints g.

[0046] The weight ratio of the powder in the intermediate coating material is preferably 10 to 500 parts by weight, more preferably 30 to 400 parts by weight, and even more preferably 50 to 300 parts by weight, relative to 100 parts by weight of the solid content of the resin component. By setting the lower limit of the weight ratio of the powder to the above value or more, the joint material c can be removed by cutting it off at the width of the joint part g when removing the joint material, so that the problem of the pattern part h peeling off together with the joint material c is suppressed, the joint material c can be removed efficiently, and the intermediate coating material used to seal the gap under the joint material is less noticeable, which is advantageous in terms of the finish of the joint part g. By setting the upper limit of the weight ratio of the powder to the above value or less, the function of sealing the gap under the joint material is fully exerted, and the finish of the joint part g can be further improved.

[0047] The weight ratio of the powder in the intermediate coating material is preferably smaller than the weight ratio of the powder in the undercoat material. Specifically, the weight ratio of the powder in the intermediate coating material is more preferably 30 parts by weight or more smaller than the weight ratio of the powder in the undercoat material, even more preferably 50 parts by weight or more smaller, and particularly preferably 80 parts by weight or more smaller. In addition, the average particle diameter of all the powder contained in the intermediate coating material is preferably smaller than the average particle diameter of all the powder contained in the undercoat material. In such a case, the above-mentioned effect is easily obtained.

[0048] The intermediate coating material may contain known additives in addition to the above components. For example, the same additives as those described in the undercoat material may be used. As long as the effect of the present invention is not significantly impaired, powders other than those described above (for example, powders with an average particle size of less than 1 μm, etc.) may also be included. The intermediate coating material can be produced by appropriately mixing the above components by a conventional method.

[0049] The intermediate coating layer e is formed by applying such an intermediate coating material to the surface of the undercoat layer b. The method of applying the intermediate coating material is not particularly limited, and for example, methods such as spray coating, roller coating, brush coating, and trowel coating can be adopted. In the present invention, roller coating is preferred, and it is preferable to use a fibrous roller as the roller. When such a fibrous roller is used, the function of sealing the gap at the bottom of the joint material is easily exerted, and the finish of the joint part g can be further improved.

[0050] A fibrous roller, for example, has a fibrous layer on the outer surface of a cylindrical core material, and the cylindrical core material is hollow so that a handle with a shaft can be attached, and the roller can be used by attaching a handle shaft to the hollow.

[0051] The material for the fibrous layer is not particularly limited, but examples thereof include pig hair, horse hair, goat hair, sheep hair, raccoon hair, etc., as well as synthetic fibers such as acrylic fibers, polyurethane fibers, polyester fibers, and polypropylene fibers.

[0052] The thickness of the fibrous layer (thickness when dry) is preferably 2 to 30 mm. The length of the fibers constituting the fibrous layer is preferably 3 to 40 mm. The fibrous layer of the above thickness can be obtained by restricting the degree of freedom of the fibers in some way, such as by weaving the fibers or fixing them at two or more points.

[0053] The width (length) of the fibrous roller is preferably 50 to 300 mm.The diameter of the fibrous roller (the outer circumference of the fibrous layer divided by pi) is preferably 15 to 100 mm.

[0054] When applying the intermediate coating material, the viscosity can be adjusted appropriately by mixing a diluent such as water. The dilution ratio is preferably 0 to 10% by weight.

[0055] The amount of intermediate coating material to be applied should be set within a range that provides sufficient gap sealing effect under the joint material, but is preferably 0.03 to 0.5 kg / m 2 , more preferably 0.05 to 0.3 kg / m 2 The intermediate coating material is preferably dried at room temperature (0 to 40°C). The drying time is preferably 1 hour or more, more preferably 2 hours or more. In the present invention, it is desirable to carry out the next step after drying the intermediate coating material layer e.

[0056] In the fourth step, a topcoat layer f is formed by applying a topcoat material to the surface of the intermediate layer e (Fig. 1 (4)). In this fourth step, it is desirable to apply the topcoat material to the entire surface, including the area where the joint material c is applied. This can improve work efficiency. As the topcoat material, for example, various materials that exhibit single or multiple colors can be used.

[0057] It is desirable to use a topcoat material with a color difference of 10 or more (more preferably 12 or more, and even more preferably 15 or more) between the undercoat layer b and the topcoat layer f. In the present invention, even when a topcoat material that meets such conditions is applied, the boundary between the joint part g and the pattern part h is finished neatly, and the contrast between the joint part g and the pattern part h is clear, so that a joint pattern with excellent aesthetics can be formed.

[0058] The color difference between the undercoat layer b and the topcoat layer f (△E fb ) is the L of each layer * Value, a * Value, b * It can be calculated from the value (average value of any 10 points) using the following formula 2. <Formula 2>△E={(L* f -L * b ) 2 +(a * f -a * b ) 2 +(b * f -b * b ) 2} 0.5 (In the formula, L * f , a * f , b * f are the L of the topcoat layer f, * , a * , b * .L * b , a * b , b * b are the L of the undercoat layer b, * , a * , b * )

[0059] As the topcoat material, for example, a material containing a resin component and a coloring pigment can be used. In such a topcoat material, the type of coloring pigment, the mixing ratio, etc. can be appropriately adjusted to set the topcoat material layer f to the desired color tone.

[0060] The resin components and coloring pigments in the topcoat material can be the same as those described for the undercoat material.

[0061] The weight ratio of the color pigment in the topcoat material is preferably 3 to 300 parts by weight, more preferably 5 to 250 parts by weight, per 100 parts by weight of the solid content of the resin component.

[0062] In addition to the above components, the topcoat material can contain the same powder as the undercoat material, and can also contain known additives. For example, the same additives as those described in the undercoat material can be used. The topcoat material can be produced by appropriately mixing the above components by conventional methods.

[0063] The topcoat layer f is formed by painting such a topcoat material on the surface of the intermediate coating layer e. The method of painting the topcoat material is not particularly limited, and for example, methods such as spray painting, roller painting, brush painting, and trowel painting can be adopted.

[0064] When applying the topcoat material, the viscosity can be adjusted appropriately by mixing a diluent such as water. The dilution ratio is preferably 0 to 20% by weight.

[0065] The amount of topcoat material applied may be set appropriately within the range in which the desired pattern is formed, but is preferably 0.03 to 1 kg / m 2 , more preferably 0.05 to 0.8 kg / m 2 The topcoat material may be dried preferably at room temperature (0 to 40° C.). The drying time is preferably 1 hour or more, more preferably 2 hours or more.

[0066] In the fifth step, the joint material c is removed (Fig. 1 (5)). By removing the joint material c, the joint area g is formed, and an aesthetically pleasing patterned surface with a difference in color tone and height between the joint area g and the pattern area h is obtained. The joint material c can be removed after the topcoat has been applied, either before or after the topcoat has dried. When removing the joint material c after the topcoat has dried, the joint material c can be removed while pressing the pattern area h using an appropriate pressing tool or the like.

[0067] After the fifth step, a clear coat material can be applied. Such application of a clear coat material is suitable in terms of improving weather resistance, water resistance, chemical resistance, durability, and contamination resistance. It is desirable to apply the clear coat material to the entire surface including the joint portion g and the pattern portion h. Examples of the clear coat material include an acrylic resin-based clear coat material, a urethane resin-based clear coat material, an acrylic silicone resin-based clear coat material, a silica-based clear coat material, and a fluororesin-based clear coat material. It is also possible to use a colored clear coat material within a range that does not impair the effects of the present invention.

[0068] In applying the clear coat material, a known method can be used, for example, various methods such as spray coating, roller coating, brush coating, etc. The amount of the clear coat material applied is preferably 0.01 to 0.5 kg / m 2 , more preferably 0.03 to 0.4 kg / m 2 The clear coat material may be dried preferably at room temperature (0 to 40° C.) The drying time is preferably 1 hour or more, and more preferably 2 hours or more.

[0069] In the present invention, in the fourth step, two or more types of topcoat materials can be applied. That is, two or more types of topcoat layers can be laminated. Figure 2 is a schematic diagram showing an example in which two types of topcoat materials are applied in the fourth step and two types of topcoat layers are laminated (topcoat layer f1, topcoat layer f2). In addition, when two or more types of topcoat materials are used, the color tone of the topcoat layer may be measured for the laminated coating film formed by the two or more types of topcoat materials.

[0070] In the method shown in FIG. 2, the steps other than the fourth step are the same as those in FIG. 1, and the details thereof are as described above.

[0071] In FIG. 2, in step 4-1, the first topcoat material is applied to the surface of the intermediate layer e to form the first topcoat layer f1 (FIG. 2(4-1)). The first topcoat material can be the same as that in FIG. 1, and the details are as described above.

[0072] Next, as a 4-2 step, the second topcoat material is applied to the surface of the first topcoat material layer f1 to form the second topcoat material layer f2 (FIG. 2(4-2)). In the present invention, it is desirable to apply the second topcoat material after the first topcoat material layer f1 has dried.

[0073] As the second topcoat material, a material capable of forming a multi-colored pattern is preferable from the viewpoint of improving aesthetics. As such a second topcoat material, a material in which liquid or gel-like color particles are dispersed in an aqueous medium can be used. As the second topcoat material, for example, materials specified in JIS K5667:2003 can be used, and the combination of the color particles and the aqueous medium constituting the second topcoat material (color particles / aqueous medium) is classified into oil-in-water type (O / W type) or water-in-water type (W / W type). In the present invention, a remarkable effect is obtained when the topcoat material is water-in-water type (W / W type). The weight ratio of the color particles to the aqueous medium (color particles: aqueous medium) is preferably 1:99 to 80:20 (more preferably 10:90 to 75:25, even more preferably 30:70 to 70:30).

[0074] The color particles in the second topcoat material are colorants containing resins, color pigments, and various additives as necessary, dispersed in a granular form in an aqueous medium in a liquid or gel state. Examples of resins in the colorants include acrylic resins, urethane resins, vinyl acetate resins, acrylic vinyl acetate resins, acrylic urethane resins, acrylic silicone resins, fluororesins, polyvinyl alcohol, biogum, galactomannan derivatives, alginic acid derivatives, and cellulose derivatives. Since such resins are in the form of water-soluble resins and / or water-dispersible resins (resin emulsions), dispersing the colorants in an aqueous medium results in a water-in-water (W / W) topcoat material.

[0075] Examples of the coloring pigment in the coloring material include the same as the coloring pigment in the undercoat material, and one or more of these can be used.

[0076] The method of dispersing the coloring material in the aqueous medium in a granular form is not particularly limited, and a known method can be adopted. Specifically, a method of dispersing the coloring material in an aqueous medium containing a dispersion stabilizer or the like can be adopted. The dispersion stabilizer is a component that stabilizes the coloring material in a granular form, and can be selected according to the type of resin and coloring material, etc. Specific examples of the dispersion stabilizer include magnesium salts, calcium salts, barium salts, aluminum salts, sodium salts, potassium salts, borates, phosphates, etc. In addition, water-soluble polymers, clays, etc. can also be used as the dispersion stabilizer. The aqueous medium can also contain the same resin (water-soluble resin, resin emulsion, etc.) as described above. In addition, when the aqueous medium contains a resin, the resin may seep into the gap under the joint material and affect the finish of the joint part g, but in the present invention, such an effect can be suppressed by the action of the intermediate coating material, etc.

[0077] In the coloring material and the aqueous medium, known additives can be appropriately used, such as extender pigments, aggregates, fillers, matting agents, fibers, gel formers, pigment dispersants, emulsifiers, thickeners, film-forming assistants, leveling agents, coupling agents, wetting agents, plasticizers, antifreeze agents, pH adjusters, dryness adjusters, preservatives, antifungal agents, anti-algae agents, antibacterial agents, defoamers, adsorbents, deodorizers, ultraviolet absorbers, light stabilizers, antioxidants, catalysts, crosslinking agents, etc.

[0078] The particle size and shape of the color particles can be set as appropriate. Specifically, the shape of the stirring blade during production, the size and position of the stirring blade relative to the stirring tank, the rotation speed of the stirring blade, the viscosity of the coloring material, the method and concentration of the dispersion stabilizer, the viscosity of the aqueous medium, etc. may be appropriately selected and adjusted. The particle size of the color particles is preferably 0.01 to 10 mm (more preferably 0.1 to 8 mm).

[0079] The second topcoat material can be applied by, for example, spray coating, roller coating, brush coating, etc. Among these, the roller can be, for example, a porous roller.

[0080] The second topcoat material can be applied once or multiple times. The amount of the second topcoat material applied is preferably 0.2 to 1.5 kg / m per application. 2 , more preferably 0.3 to 1.2 kg / m 2 It is.

[0081] When applying the second topcoat material, the viscosity can be adjusted appropriately by mixing a diluent such as water. The dilution ratio is preferably 0 to 10% by weight.

[0082] When using a second topcoat material, it is desirable to set the color tone of the first topcoat material layer f1 to a color tone (common color) similar to that of the second topcoat material layer f2. This allows for a finish with excellent aesthetics and no sense of incongruity even when the first topcoat material layer f1 is visible between the color particles of the second topcoat material layer f2. EXAMPLES

[0083] Examples and comparative examples will be given below to clarify the features of the present invention.

[0084] ·Undercoating material 1 A dark gray primer 1 was produced by uniformly mixing 100 parts by weight of solids of a cross-linking reactive resin {a mixture of a carbonyl group-containing acrylic resin emulsion (Tg 20°C) and adipic dihydrazide, solids content 50% by weight} with 24 parts by weight of coloring pigments (carbon black, red iron oxide, yellow iron oxide), 320 parts by weight of powdered material {calcium carbonate (average particle size 32 μm, refractive index 1.6) and kaolin (average particle size 5 μm, refractive index 1.6), average particle size of all powdered material 20 μm}, and other additives (film-forming aid, thickener, defoamer, preservative, etc.).

[0085] ·Intermediate coating material 1 A dark gray intermediate coating material 1 was produced by uniformly mixing 100 parts by weight of the solid content of the cross-linking reactive resin (same as above) with 24 parts by weight of coloring pigments (carbon black, red iron oxide, yellow iron oxide), 170 parts by weight of powdered material {calcium carbonate (average particle size 4 μm, refractive index 1.6) and kaolin (average particle size 5 μm, refractive index 1.6), total powdered material average particle size 5 μm}, and other additives (film-forming aid, thickener, defoamer, preservative, etc.).

[0086] ·Intermediate coating material 2 A dark gray intermediate coating material 2 was produced by uniformly mixing 100 parts by weight of the solid content of the cross-linking reactive resin (same as above), 24 parts by weight of the color pigment (same as above), 105 parts by weight of powder and granules {calcium carbonate (average particle size 2 μm, refractive index 1.6) and kaolin (average particle size 8 μm, refractive index 1.6), average particle size of all powder and granules 4 μm}, and other additives (same as above).

[0087] ·Intermediate coating material 3 A dark gray intermediate coating material 3 was produced by uniformly mixing 100 parts by weight of the solid content of the cross-linking reactive resin (same as above), 24 parts by weight of the color pigment (same as above), 220 parts by weight of powder and granules {calcium carbonate (average particle size 2 μm, refractive index 1.6) and talc (average particle size 12 μm, refractive index 1.6), average particle size of all powder and granules 8 μm}, and other additives (same as above).

[0088] ·Intermediate coating material 4 A dark gray intermediate coating material 4 was produced by uniformly mixing 100 parts by weight of the solid content of the cross-linking reactive resin (same as above), 24 parts by weight of the color pigment (same as above), and other additives (same as above).

[0089] ·Top coating material 1 A pale gray topcoat material 1 was produced by uniformly mixing 100 parts by weight of solids of a cross-linking reactive resin {acrylic silicone resin emulsion (Tg 16°C, solids content 50% by weight)} with 62 parts by weight of coloring pigments (titanium oxide, carbon black, red iron oxide, yellow iron oxide) and other additives (aggregates, film-forming agents, thickeners, defoamers, preservatives, etc.).

[0090] ·Top coating material 2 A topcoat material 2 was produced containing 15 parts by weight of gel-like color particles 1 (light yellow gel-like particles; acrylic silicone resin emulsion, titanium oxide, yellow iron oxide, red oxide, granulated colorant mainly composed of water, particle diameter 1 to 3 mm), 25 parts by weight of gel-like color particles 2 (light gray gel-like particles; acrylic silicone resin emulsion, black iron oxide, titanium oxide, granulated colorant mainly composed of water, particle diameter 0.5 to 2 mm), 10 parts by weight of gel-like color particles 3 (brown gel-like particles; acrylic silicone resin emulsion, red oxide, yellow iron oxide, black iron oxide, titanium oxide, granulated colorant mainly composed of water, particle diameter 1 to 3 mm), and 50 parts by weight of aqueous medium (acrylic silicone resin emulsion, aqueous medium mainly composed of water).

[0091] Example 1 Apply 0.3 kg / m of primer 1 to the entire surface of a 45 x 30 cm substrate (slate board). 2 The coating was applied using a porous roller (pore size of the porous layer: 1 mm) at 100°C, and after drying for 16 hours, a peelable joint material was applied. Note that a lattice-shaped template (thickness: 0.8 mm, width: 6 mm) with an adhesive layer on the back was used as the peelable joint material.

[0092] Next, apply intermediate coating material 1 at a rate of 0.1 kg / m 2 The entire surface was painted with a fiber roller (fiber layer thickness 13 mm) and dried for 3 hours. Then, topcoat material 1 was applied at a coating amount of 0.4 kg / m 2 The entire surface was painted with a porous roller (pore diameter of the porous layer: 1 mm). After drying for 3 hours, topcoat material 2 was applied at a coating amount of 0.4 kg / m 2 The entire surface was painted twice using a porous roller (pore diameter of the porous layer: 3 mm) and then dried for 24 hours. After that, the peelable joint material was removed.

[0093] Color difference between the undercoat layer 1 (undercoat layer 1 coating) and the intermediate coat layer 1 (intermediate coat layer 1 coating) (△E eb The color difference (ΔE fb ) was 45.

[0094] The patterned surface obtained by the above steps had a neat, straight-line finish with clear boundaries between the joints and the patterned areas, and the contrast between the joints and the patterned areas was also clear, resulting in a joint pattern with excellent aesthetic appeal.

[0095] Example 2 Except for using intermediate coating material 2 instead of intermediate coating material 1, painting was carried out in the same manner as in Example 1. The color difference (ΔE eb ) was 0.6. The patterned surface obtained in Example 2, like Example 1, had a neat, straight-line finish with a boundary between the joints and the patterned areas, and the contrast between the joints and the patterned areas was clear, resulting in a joint pattern with excellent aesthetic appeal.

[0096] Example 3 Except for using intermediate coating material 3 instead of intermediate coating material 1, painting was carried out in the same manner as in Example 1. The color difference (ΔE eb ) was 0.5. The patterned surface obtained in Example 3, like Example 1, had a neat, straight-line finish with a boundary between the joints and the patterned areas, and the contrast between the joints and the patterned areas was clear, resulting in a joint pattern with excellent aesthetic appeal.

[0097] Example 4 Except for using intermediate coating material 4 instead of intermediate coating material 1, painting was carried out in the same manner as in Example 1. The color difference (ΔE eb ) was 0.6. The patterned surface obtained in Example 4 had a generally linear boundary between the joints and the patterned portion. The contrast between the joints and the patterned portion was clear, and the aesthetics were also good.

[0098] Comparative Example 1 When painting was carried out in the same manner as in Example 1, except for omitting the painting process of the intermediate coating material 1, the resulting patterned surface had a jagged finish at the boundary between the joints and the patterned area, and did not exhibit the aesthetic quality of Example 1.

Claims

1. A method for forming a patterned surface having a joint pattern, comprising the steps of: (1) A first step of applying a primer to a substrate to form a primer layer; (2) A second step of installing a peelable joint material on the surface of the undercoat layer; (3) A third step of applying an intermediate coating material to the surface obtained in the second step to form an intermediate coating material layer; (4) A fourth step of applying a topcoat material to the surface of the intermediate coating material layer to form a topcoat material layer; (5) A fifth step of removing the joint material; The purpose is to The color difference between the undercoat layer and the intermediate coat layer is less than 10; The undercoat material contains a resin component, a color pigment, and a powder having an average particle diameter of 1 μm or more and a refractive index of 1.3 to 1.7, The intermediate coating material contains a resin component, a color pigment, and a powder having an average particle diameter of 1 μm or more and a refractive index of 1.3 to 1.7, A method for forming a patterned surface, characterized in that the weight ratio of the powder and granules in the intermediate coating material is smaller than the weight ratio of the powder and granules in the undercoat material.

2. The method for forming a patterned surface according to claim 1, characterized in that the undercoat material contains 50 to 600 parts by weight of the powder and granules per 100 parts by weight of solid content of the resin component.

3. The method for forming a patterned surface according to claim 1 or 2, characterized in that the intermediate coating material contains 10 to 300 parts by weight of the powder and granules per 100 parts by weight of the solid content of the resin component.

4. The method for forming a patterned surface according to any one of claims 1 to 3, characterized in that the color difference between the undercoat layer and the topcoat layer is 10 or more.

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