Film formation method

Abstract

To provide an efficient film formation method for imparting a uniform spot pattern to an existing wall surface in a construction site by roller painting.SOLUTION: A film formation method coats a top coating material on to a wall surface by roller coating, wherein the top coating material contains synthetic resin emulsion (m), and lightweight colored particles (n) having a bulk density of 1.0 g / ml or less and an average particle size of 0.01-1 mm as essential components, and the lightweight colored particles (n) contain at least two or more kinds of different color lightweight colored particles, and contain 0.1-50 pts.wt. of the light colored particles (n) with respect to 100 pts.wt. of a solid content of the synthetic resin emulsion (m).SELECTED DRAWING: None

Description

[Technical Field]

[0001] This invention relates to a novel method for forming a coating. [Background technology]

[0002] Conventionally, inorganic building materials such as siding boards and ALC panels have been commonly used as materials for the walls of buildings. In painting such inorganic building materials, techniques such as applying a speckled pattern to the surface have been employed to enhance their aesthetic appeal. For example, Patent Document 1 describes a method of forming a speckled pattern by spray painting using a colored coating material prepared to a specific viscosity, while controlling the pattern and discharge amount during painting. Patent Document 2 describes a method of applying a base coating material, and then unevenly applying a colored coating material of a different color from the base coating material.

[0003] However, these methods all relate to painting methods used in factories, and they create a speckled pattern by mechanically controlling the application of colored paint through sputter painting. Inorganic building materials installed as wall materials at construction sites deteriorate over time and require repainting, but even if one attempts to apply the methods described in the above patent documents to painting at such construction sites, it is difficult to consistently obtain speckled patterns of the desired size, and the methods currently lack practicality.

[0004] On the other hand, a method is known in which a spotted pattern is applied to inorganic building materials by coating them with a topcoat material in which aggregates such as silica sand and mica are dispersed in a resin liquid. With this method, a spotted pattern of a desired size can be obtained by setting the particle size of the aggregate used. For example, Patent Document 3 describes a method of coating a laminated multi-colored patterned coating film with a clear topcoat material containing flat colored material such as mica. [Prior art documents] [Patent Documents]

[0005] [Patent Document 1] Japanese Patent Application Publication No. 3-186381 [Patent Document 2] Japanese Utility Model Publication No. 4-77440 [Patent Document 3] Patent No. 6180678 [Overview of the Initiative] [Problems that the invention aims to solve]

[0006] However, when applying topcoats containing aggregates such as silica sand and mica, as described above, using a roller as the application tool can cause the aggregates to clump together on the surface, potentially resulting in unevenness in the spotted pattern and making it difficult to obtain a uniform spotted pattern.

[0007] Furthermore, while Patent Document 3 describes a topcoat containing black mica, such a topcoat can only be applied when the surface to be coated is light in color. Its applicability is limited, and a separate topcoat must be prepared for dark-colored surfaces. Applying a topcoat containing black mica to a dark-colored surface makes it difficult to achieve the desired aesthetic effect.

[0008] This invention has been made in view of the above-mentioned problems, and aims to provide an efficient method for forming a coating on existing wall surfaces at construction sites and the like by roller painting, thereby creating a uniform speckled pattern. [Means for solving the problem]

[0009] As a result of diligent research to achieve the above objective, the inventors of the present invention conceived of a method for roller-applying a specific topcoat material containing at least two types of specific lightweight colored particles to a wall surface, and thus completed the present invention.

[0010] In other words, the present invention has the following features. 1. A method for forming a coating on a wall surface by roller application of a topcoat material, As the topcoat material, a synthetic resin emulsion (m) and lightweight colored particles (n) with a bulk density of 1.0 g / ml or less and an average particle diameter of 0.01 to 1 mm are used as essential components. The above lightweight colored particles (n) contain at least two or more types of lightweight colored particles of different colors. A topcoat material is used which contains 0.1 to 50 parts by weight of the above lightweight colored particles (n) with respect to 100 parts by weight of the solid content of the above synthetic resin emulsion (m). A film-forming method characterized by this. 2. The film-forming method according to 1., characterized in that the above lightweight colored particles (n) contain at least two or more types of lightweight colored particles with a lightness difference of 30 or more. 3. The film-forming method according to 1. or 2., characterized in that the above lightweight colored particles (n) are granular. 4. The film-forming method according to any one of 1. to 3., characterized in that as the above roller, a fibrous roller with a pile length of 10 mm or more is used. 5. The film-forming method according to any one of 1. to 4., characterized in that after coating a primer and / or an intermediate coat on the wall surface, the above topcoat material is applied by roller coating.

Effects of the Invention

[0011] According to the present invention, a uniform mottled pattern can be efficiently formed on an existing wall surface at a construction site or the like by roller coating, and a highly aesthetic finish can be easily obtained.

Brief Description of the Drawings

[0012] [Figure 1] It is a diagram showing an example of a roller.

Embodiments for Carrying Out the Invention

[0013] Hereinafter, embodiments for carrying out the present invention will be described.

[0014] The surface to be painted in this invention is an existing wall surface of a building, civil engineering structure, etc. Examples of base materials constituting the wall surface include concrete, mortar, cement board, extruded board, slate board, PC board, ALC board, fiber-reinforced cement board, metal siding board, ceramic siding board, ceramic board, calcium silicate board, gypsum board, plastic board, hard wood chip cement board, PVC extruded siding board, plywood, etc., or those having a coating on their surface. This invention is particularly suitable for existing wall surfaces composed of inorganic building materials such as siding boards and ALC boards. When the wall surface is composed of multiple inorganic building materials, the joints between the inorganic building materials may be filled with jointing materials such as sealants and dry joint materials.

[0015] In the present invention, a primer and / or intermediate coat can be applied to the wall surface described above before applying the topcoat.

[0016] Among these, the undercoat material can be one that has at least one function selected from, for example, adhesion, water permeability resistance, substrate reinforcement, opacity, substrate preparation, and substrate conformability. Examples of such undercoat materials include fillers, surfacers, sealers, and primers. In the present invention, one or more types of undercoat materials can be used as needed.

[0017] As an intermediate coating material, for example, one with color-developing properties can be used. By using such an intermediate coating material, the desired color can be imparted to the surface to be coated before the topcoat is applied. The intermediate coating material may also have at least one function selected from, for example, weather resistance, durability, heat shielding, opacity, and waterproofing. If the intermediate coating material has sufficient performance, for example, adhesion to the surface to be coated, then the application of a primer is not essential.

[0018] As the intermediate coating material, for example, one containing a binder and a coloring pigment can be used. Examples of binders include various resins such as acrylic resin, urethane resin, epoxy resin, vinyl acetate resin, silicone resin, fluororesin, acrylic vinyl acetate resin, acrylic urethane resin, acrylic silicone resin, etc., or composite resins thereof. These can be used individually or in combination of two or more. As such binders, aqueous resins such as water-dispersible resins (resin emulsions) and water-soluble resins are preferably used. The glass transition temperature of the binder (a value obtained from FOX's formula) is preferably 60°C or lower, more preferably -50 to 50°C. In this invention, "α to β" is synonymous with "α or more and β or less".

[0019] Examples of coloring pigments include titanium dioxide, zinc oxide, alumina, carbon black, graphite, black iron oxide, iron-manganese composite oxide, iron-copper-manganese composite oxide, iron-chromium-cobalt composite oxide, copper-chromium composite oxide, copper-manganese-chromium composite oxide, ferric oxide (red iron oxide), molybdate orange, permanent red, permanent carmine, anthraquinone red, perylene red, quinacridone red, yellow iron oxide, titanium yellow, first yellow, benzoimidazolone yellow, chromium green, cobalt green, phthalocyanine green, ultramarine, Prussian blue, cobalt blue, phthalocyanine blue, quinacridone violet, dioxazine violet, aluminum pigment, pearl pigment, etc. These can be used individually or in combination of two or more. By using one or more of these coloring pigments as appropriate, the color tone of the intermediate coating film can be adjusted. The average particle size of the coloring pigment is preferably 2 μm or less, more preferably 0.01 to 1 μm. The average particle size of the pigment is the average value measured using a laser diffraction particle size distribution analyzer (measurement temperature 25°C).

[0020] In addition to the components mentioned above, the intermediate coating material may also contain, for example, extender pigments, dyes, aggregates, color particles, matting agents, thickeners, wetting agents, leveling agents, antifreeze agents, film-forming aids, preservatives, antifungal agents, antialgal agents, antibacterial agents, dispersants, surfactants, defoaming agents, UV absorbers, light stabilizers, antioxidants, adhesion promoters, destaining agents, hydrophilic agents, water repellents, crosslinking agents, hardening agents, hardening accelerators, plasticizers, coupling agents, adsorbents, pH adjusters, catalysts, water, solvents, etc. The intermediate coating material can be manufactured by uniformly mixing such components by conventional methods.

[0021] The pigment volume concentration (PVC) of the intermediate coating material is preferably 50% or less, more preferably 30% or less, even more preferably 5-28%, and particularly preferably 8-25%. The use of such an intermediate coating material is advantageous in terms of substrate conformability (such as conformability to wall surfaces with joints filled with sealant, etc.) and the ability to create a finish that takes advantage of the texture of the coated surface. The pigment volume concentration is the volume percentage of pigment contained in the dried film and is a value calculated from the mixed amount of resin and pigment constituting the intermediate coating material. The specific gravity of the resin is assumed to be 1.

[0022] For applying the intermediate coating material, known methods can be employed. Examples of application methods include spray application, roller application, and brush application. For roller application, a fibrous roller is preferably used. The application amount of the intermediate coating material is preferably 0.05 to 0.8 kg / m². 2 More preferably 0.1~0.6 kg / m 2 The viscosity can be adjusted as needed by mixing in a diluent such as water during painting. The intermediate coating material should preferably be dried at room temperature (0-40°C). When the intermediate coating material is applied, the topcoat material can be applied after the intermediate coating film has dried.

[0023] In applying the intermediate coating material, the entire wall surface can be painted with one type (one color) of intermediate coating material, or two or more types of intermediate coating materials with different color tones can be used. In the latter case, for example, a multi-color pattern with two or more colors can be formed by painting the entire surface with a first intermediate coating material and then partially painting with a second intermediate coating material (of a different color from the first intermediate coating material), or by painting the first and second intermediate coating materials in predetermined areas. In this invention, by applying the intermediate coating material in this way, it is possible to impart the desired color to the surface while also making use of the texture of the surface.

[0024] The intermediate coating film formed by applying the intermediate coating material may be either glossy or matte (including 70% gloss, 50% gloss, 30% gloss, etc.).

[0025] In this invention, a topcoat material is applied to the wall surface described above using a roller. The topcoat material in this invention contains a synthetic resin emulsion (m) and two or more specific lightweight colored particles (n) as essential components. In this invention, by applying such a specific topcoat material with a roller, it is possible to efficiently form a uniform speckled pattern. The final finished appearance is a speckled pattern formed by the lightweight colored particles (n) on the background color (the color of the surface to be coated before the topcoat material is applied; if an intermediate coat material is applied, the color of the intermediate coat material film), resulting in excellent design aesthetics. The topcoat material of this invention can form speckled patterns on a wide range of background colors, giving it a broad range of applications. According to this invention, there is no need to prepare numerous topcoat materials according to the background color, making it efficient. Moreover, because the lightweight colored particles (n) contained in the topcoat material are light and small, they are easily dispersed, and it is believed that the dispersion of these lightweight colored particles (n) is promoted during roller application, enabling the formation of a uniform speckled pattern.

[0026] Among the components constituting the topcoat material, the synthetic resin emulsion (m) (hereinafter also referred to as "(m) component") acts as a binder. The (m) component can be one that forms a transparent film. Specifically, examples of (m) components include vinyl acetate resin emulsion, epoxy resin emulsion, acrylic resin emulsion, urethane resin emulsion, acrylic silicone resin emulsion, fluororesin emulsion, etc., or composite resin emulsions thereof. Among these, acrylic resin emulsion, urethane resin emulsion, acrylic silicone resin emulsion, fluororesin emulsion, etc., or composite resin emulsions thereof are preferred from the viewpoint of weather resistance, etc. The (m) component can be used individually or in combination of two or more types, and two or more types of (m) components can also be mixed. The (m) component may also have crosslinking reactivity.

[0027] Component (m) can be produced, for example, by a one-stage or multi-stage (two-stage or three or more-stage) emulsion polymerization method. When multi-stage emulsion polymerization is employed, for example, a multilayer emulsion (such as a core-shell emulsion) can be obtained.

[0028] The average particle size of component (m) is preferably 30 to 500 nm, more preferably 50 to 300 nm. The average particle size of component (m) can be measured using a dynamic light scattering analyzer (measurement temperature 25°C).

[0029] The glass transition temperature of the resin constituting component (m) is preferably -30 to 80°C, more preferably -20 to 60°C. The glass transition temperature can be determined by Fox's formula.

[0030] The lightweight colored particles (n) in the topcoat material (hereinafter also referred to as "(n) component") shall have a bulk density of 1.0 g / ml or less and an average particle diameter of 0.01 to 1 mm. At least two types of lightweight colored particles that meet these conditions can be used as the (n) component.

[0031] The bulk density of component (n) is 1.0 g / ml or less, preferably 0.01 to 0.95 g / ml, more preferably 0.1 to 0.9 g / ml, and even more preferably 0.2 to 0.8 g / ml. When the bulk density of component (n) is within the above range, it is possible to form a homogeneous spotted pattern, which is also advantageous in terms of paintability and other aspects. If the bulk density of component (n) exceeds the above upper limit, the particles tend to clump together on the surface to be painted during roller painting, which may cause unevenness in the spotted pattern. The bulk density in this invention is a value measured by supplying lightweight colored particles to a cylindrical container and applying vertical vibration (tapping vibration) until the bulk change of the lightweight colored particles in the container is complete.

[0032] The average particle size of component (n) is 0.01 to 1 mm, preferably 0.02 to 0.5 mm, and more preferably 0.03 to 0.3 mm. When the average particle size of component (n) is within the above range, it is possible to form a homogeneous spotted pattern, which is also advantageous in terms of paintability and other factors. If the average particle size of component (n) is smaller than the lower limit, the spotted pattern will be difficult to recognize on the finished surface after painting. If the average particle size of component (n) is larger than the upper limit, the aggregation of particles and the convex shape of the particles will become more noticeable, which is disadvantageous in terms of finish and aesthetics. In addition, there is a risk that the paintability will decrease.

[0033] The shape of component (n) is not particularly limited, but in the present invention, a granular shape is preferred. Here, granular means a shape in which the average particle diameter and average thickness are approximately equal. Specifically, as component (n), a ratio of average particle diameter to average thickness (average particle diameter / average thickness) of 2 or less (preferably 1.5 or less) is preferred. Using such a shape is even more preferable in terms of homogenizing the spotted pattern and can improve the aesthetic appearance of the formed film.

[0034] Note that the average particle diameter of component (n) is the average of the major axis when a particle placed on a horizontal surface in its most stable orientation is observed from above. The average thickness is the average of the interplanar spacing when a particle placed on a horizontal surface in its most stable orientation is sandwiched between horizontal planes.

[0035] The topcoat material of the present invention contains at least two types of lightweight colored particles of different colors as component (n). Specifically, component (n) includes at least a first lightweight colored particle (hereinafter also referred to as "component (n1)") and a second lightweight colored particle of a different color from the first colored particle (hereinafter also referred to as "component (n2)"). This broadens the range of application of the topcoat material and allows for the formation of a speckled pattern on a wide range of background colors. Component (n1) and component (n2) can be any color tones, as long as they have different color tones from each other.

[0036] In this invention, "different colors" refers to colors whose tones are so different that they can be visually recognized as different. The color difference (△E) is preferably 5 or more, more preferably 10 or more, even more preferably 20 or more, and particularly preferably 30 or more. The color difference (△E) is measured using a colorimeter. * value, a * value, b * This value is calculated based on the values. For particles of component (n), the particles are placed on a glass plate until the glass surface is obscured, and the surface covered with a colorless, transparent PE film is used for measurement.

[0037] In the present invention, it is desirable that the (n) component contains at least two types of lightweight colored particles with a lightness difference of 30 or more. That is, it is desirable to include component (n1) and component (n2) with a mutual lightness difference of 30 or more. This allows the effects of the present invention to be fully realized and a high-quality, aesthetically pleasing finish to be stably obtained. The lightness difference between component (n1) and component (n2) is more preferably 35 to 100, and even more preferably 40 to 95. Note that the lightness difference is the lightness L of component (n1). * The value and the brightness L of the (n2) component. * It is the absolute value of the difference between the given value and the given value.

[0038] In this invention, by including component (n) of the above embodiment in the topcoat material, it is possible to reliably obtain a spotted pattern of a different color from the background color before the topcoat material is applied. That is, the spotted pattern consisting of at least one of component (n1) and component (n2) can be clearly seen against a wide range of background colors. Even when two or more intermediate coating materials are used to apply different colors before the topcoat material is applied, the spotted pattern consisting of at least one of component (n1) and component (n2) can be clearly seen.

[0039] As component (n), for example, materials based on rubber, resin, minerals, wood, plants, etc., can be used, and organic particles based on rubber or resin are particularly preferred. As long as the bulk density, average particle diameter, etc., of such component (n) satisfy the above conditions, its internal structure is not particularly limited, and examples include solid bodies, foams, porous bodies, etc. The color of component (n) may, for example, be the original color of the base material, or it can be imparted by applying a coloring treatment to the base material (for example, coloring treatment of the inside of the base material, colored coating of the surface of the base material, etc.).

[0040] The amount of component (n) mixed is 0.1 to 50 parts by weight, preferably 0.5 to 30 parts by weight, and more preferably 1 to 20 parts by weight, per 100 parts by weight of the solid content of component (m). By having the amount of component (n) mixed within this range, it is possible to form a highly aesthetic, homogeneous spotted pattern with spots on the background color. If the amount of component (n) mixed exceeds the above upper limit, unevenness is likely to occur in the spotted pattern, and the background color of the underlying layer is more likely to be obscured, which is disadvantageous in terms of spotted pattern formation. If the amount of component (n) mixed is less than the above lower limit, the spotted pattern will be difficult to recognize on the finished surface after painting.

[0041] The (n1) component and the (n2) component can be mixed within a range where the weight ratio of (n1):(n2) is preferably 1:9 to 9:1, more preferably 2:8 to 8:2, and even more preferably 3:7 to 7:3. In the topcoat material of the present invention, the effects of the present invention can also be exhibited in a form in which the (n) component contains only the (n1) component and the (n2) component. In the topcoat material of the present invention, if necessary, the (n) component may further contain lightweight colored particles of a different color from the (n1) component and the (n2) component.

[0042] The topcoat material may contain, within limits that do not impair the effects of the present invention, for example, coloring pigments, extender pigments, dyes, matting agents, thickeners, wetting agents, leveling agents, antifreeze agents, film-forming aids, preservatives, antifungal agents, antialgal agents, antibacterial agents, dispersants, surfactants, defoaming agents, ultraviolet absorbers, light stabilizers, antioxidants, adhesion promoters, destaining agents, hydrophilic agents, water repellents, crosslinking agents, curing agents, curing accelerators, plasticizers, coupling agents, adsorbents, pH adjusters, catalysts, water, solvents, etc. The topcoat material can be manufactured by uniformly mixing such components by conventional methods.

[0043] The heat residue of the topcoat material is preferably 10-80% by weight, more preferably 20-60% by weight, and even more preferably 30-55% by weight. The heat residue can be measured according to the method specified in JIS K5601-1-2 "Heat Residue" (heating temperature 135°C, heating time 60 minutes).

[0044] The topcoat film formed by the topcoat material has a mottled pattern due to the scattering of component (n) within the transparent film. In other words, it has transparency that allows the background color before the topcoat material is applied to be visible. The transparent film formed by the topcoat material may be colorless transparent or colored transparent, and may be glossy or matte (including 70% gloss, 50% gloss, 30% gloss, etc.). Of these, the colored transparent film can be formed by a topcoat material containing, for example, colored pigments, dyes, etc., and the degree of coloring should be set within a range in which the background color and mottled pattern can be visible. The matte film can be formed by a topcoat material containing, for example, extender pigments, matting agents, etc.

[0045] The topcoat material of the present invention is different from materials referred to as multi-color pattern paints (multicolor paints), stone-like finish coatings (stone-like paints), etc. Generally, multi-color pattern paints contain a high proportion of liquid or gel-like color particles, and these color particles form a multi-color pattern, while stone-like finish coatings contain a high proportion of colored aggregates or natural aggregates, and the color of these aggregates creates a stone-like texture. In contrast, the topcoat material of the present invention, with the above-described structure, forms a spotted pattern with scattered lightweight colored particles (n). The main color is expressed by the background color.

[0046] In this invention, the topcoat material is applied using a roller. This roller application method suppresses scattering of the topcoat material and improves its adhesion to the surface to be coated. Examples of rollers that can be used include fibrous rollers and porous rollers. Of these, fibrous rollers are preferred in this invention.

[0047] In this invention, it is desirable to apply the topcoat using a fibrous roller with a pile length of 10 mm or more. This makes it possible to form a more uniform speckled pattern. This effect is thought to be achieved because the long fibers of the fibrous roller sufficiently promote the dispersion of these lightweight coloring particles (n) during roller application.

[0048] An example of such a roller is shown in Figure 1. The roller in Figure 1 is a fibrous roller, in which a fibrous layer is provided on the outer surface of a cylindrical core. The cylindrical core is hollow so that a handle with an axle can be attached, and the handle can be attached to the hollow for use. As the cylindrical core, for example, a core made of plastic, wood, metal, or paper can be used, and in order to improve the ease of attachment between the handle axle and the core, an attachment aid can be provided between the handle axle and the core. The outer diameter of the fibrous roller is preferably 30 to 80 mm. The length of the fibrous roller is preferably 50 to 300 mm.

[0049] The pile length of the fibrous roller is preferably 10 mm or more, more preferably 12 mm or more, even more preferably 15 to 40 mm, particularly preferably 18 to 38 mm, and most preferably 20 to 36 mm. The pile length refers to the length of the fibers that make up the fibrous roller. Specifically, the pile length can be determined by lightly pinching the fibers of a dry fibrous roller with your fingers, stretching them outward from the core material, measuring the length of the fibers, and calculating the average value. A fibrous roller with such a pile length is even more advantageous in terms of forming a uniform speckled pattern.

[0050] Examples of materials for the fibers constituting the fibrous layer include pig hair, horsehair, goat hair, sheep's wool, badger hair, human hair, silk, cotton, etc., or synthetic fibers such as acrylic fibers, polyurethane fibers, polyester fibers, and polypropylene fibers. The fibrous layer can be formed by knitting or weaving together aggregates of such fibers (for example, cotton-like piles, thread-like piles, etc.).

[0051] When applying a topcoat using such a fibrous roller, the viscosity of the topcoat can be set as appropriate. The topcoat can be diluted with water or other liquids as needed. The viscosity of the topcoat (during application) is preferably 0.1 to 15 Pa·s, more preferably 0.3 to 13 Pa·s. The thixotropy index of the topcoat (during application) is preferably 6 or less, more preferably 1 to 5. The viscosity is determined by measuring the viscosity at 20 rpm (the indicator value at the 4th rotation) using a BH-type viscometer. The thixotropy index (TI) is determined using a BH-type viscometer and the following formula. In all cases, the measurement temperature is 23°C. <Formula> TI = η1 / η2 (In the formula, η1 is the viscosity at 2 rpm (Pa·s: indicator value at the 2nd rotation). η2 is the viscosity at 20 rpm (Pa·s: indicator value at the 4th rotation).)

[0052] The topcoat material in this invention can be applied to the entire wall surface. The amount of topcoat material to be applied is preferably 50 g / m². 2More preferably, it is 100 to 500 g / m 2 Even more preferably, it is 105 to 400 g / m 2 The number of coats of the topcoat is preferably 1 to 2 times, more preferably 1 time. By applying the topcoat under such conditions, a relatively thick film state is obtained, and the dispersion of the lightweight coloring particles (n) is more easily promoted, which is more advantageous in terms of forming a uniform speckled pattern.

[0053] Drying after applying the topcoat may preferably be performed at room temperature (0 to 40°C). The drying time is preferably 1 hour or more, preferably about 2 to 24 hours.

[0054] In the present invention, the aesthetic appearance of an existing wall surface at a construction site or the like can be enhanced by the film-forming method as described above. The present invention is suitable for performing such wall surface renovation (modification). By applying the film-forming method of the present invention to a wall surface that has deteriorated over time, the aesthetic appearance of the wall surface can be enhanced, and it is also possible to restore the color at the time of new construction, and it is also possible to impart a new color different from that at the time of new construction. For a wall surface composed of inorganic building materials such as siding boards and ALC boards and having a joint part filled with a sealing material or the like at the joint between the inorganic building materials, the method of the present invention can also be applied to the entire surface including the inorganic building materials and the joint part.

Examples

[0055] Examples and comparative examples are shown below to clarify the features of the present invention. Note that the present invention is not limited to the examples here.

[0056] The following were prepared as the topcoat. · Topcoat 1 To 200 parts by weight of synthetic resin emulsion a (acrylic silicone resin emulsion, solids content 50% by weight, glass transition temperature 32°C, average particle size 110 nm), 2 parts by weight of lightweight colored particles a (black resin particles, bulk density 0.68 g / ml, average particle size 0.1 mm, average particle size / average thickness = 1.0, lightness 26), 2 parts by weight of lightweight colored particles d (white resin particles, bulk density 0.72 g / ml, average particle size 0.1 mm, average particle size / average thickness = 1.0, lightness 91), 12 parts by weight of film-forming aid, 1 part by weight of ultraviolet absorber, 2 parts by weight of viscosity modifier, and 3 parts by weight of defoamer were mixed, and water was further added to adjust the heat residue to 40% by weight, thereby obtaining topcoat material 1. The difference in lightness between lightweight colored particles a and lightweight colored particles d was 65.

[0057] ·Top coating material 2 To 200 parts by weight of synthetic resin emulsion b (acrylic resin emulsion, solids content 50% by weight, glass transition temperature 34°C, average particle size 150 nm), 4 parts by weight of lightweight colored particles b (black resin particles, bulk density 0.68 g / ml, average particle size 0.08 mm, average particle size / average thickness = 1.0, lightness 25), 4 parts by weight of lightweight colored particles e (white resin particles, bulk density 0.72 g / ml, average particle size 0.08 mm, average particle size / average thickness = 1.0, lightness 91), 12 parts by weight of film-forming aid, 2 parts by weight of viscosity modifier, and 3 parts by weight of defoamer were mixed, and water was further added to adjust the heat residue to 45% by weight, thereby obtaining topcoat material 2. The difference in lightness between lightweight colored particles b and lightweight colored particles e was 66.

[0058] ·Top coating material 3 To 200 parts by weight of synthetic resin emulsion c (acrylic silicone resin emulsion, solids content 50% by weight, glass transition temperature 38°C, average particle size 100 nm), 1 part by weight of lightweight colored particles c (black resin particles, bulk density 0.69 g / ml, average particle size 0.15 mm, average particle size / average thickness = 1.0, lightness 26), 1 part by weight of lightweight colored particles f (white resin particles, bulk density 0.74 g / ml, average particle size 0.15 mm, average particle size / average thickness = 1.0, lightness 90), 12 parts by weight of film-forming aid, 1 part by weight of ultraviolet absorber, 2 parts by weight of viscosity modifier, and 3 parts by weight of defoamer were mixed, and water was further added to adjust the heat residue to 42% by weight, thereby obtaining topcoat material 3. The difference in lightness between lightweight colored particles c and lightweight colored particles f was 64.

[0059] ·Top coating material 4 A topcoat material 4 was obtained in the same manner as topcoat material 1, except that the amount of lightweight colored particles a was 6 parts by weight and the amount of lightweight colored particles d was 6 parts by weight.

[0060] ·Top coating material 5 A topcoat material 5 was obtained in the same manner as topcoat material 1, except that the amount of lightweight colored particles a mixed in was 16 parts by weight and the amount of lightweight colored particles d mixed in was 16 parts by weight.

[0061] ·Top coating material 6 To 200 parts by weight of synthetic resin emulsion a (same as above), 4 parts by weight of black silica sand (bulk density 1.2 g / ml, average particle diameter 0.12 mm, average particle diameter / average thickness = 1.2), 12 parts by weight of film-forming aid, 1 part by weight of ultraviolet absorber, 2 parts by weight of viscosity modifier, and 3 parts by weight of defoamer were mixed, and then water was added to adjust the heat residue to 40% by weight to obtain topcoat material 6.

[0062] ·Top coating material 7 To 200 parts by weight of synthetic resin emulsion a (same as above), 4 parts by weight of black mica (bulk density 0.40 g / ml, average particle diameter 0.12 mm, average particle diameter / average thickness = 28), 12 parts by weight of film-forming aid, 1 part by weight of ultraviolet absorber, 2 parts by weight of viscosity modifier, and 3 parts by weight of defoamer were mixed, and water was further added to adjust the heat residue to 40% by weight, thereby obtaining topcoat material 7.

[0063] ·Top coating material 8 To 200 parts by weight of synthetic resin emulsion a (same as above), 2 parts by weight of lightweight colored particles a (same as above), 2 parts by weight of lightweight colored particles d (same as above), 12 parts by weight of film-forming aid, 50 parts by weight of matting agent (uncolored resin particles, average particle size 15 μm), 1 part by weight of ultraviolet absorber, 2 parts by weight of viscosity modifier, and 3 parts by weight of defoamer were mixed, and water was further added to adjust the heat residue to 40% by weight, thereby obtaining topcoat material 8.

[0064] The following rollers were prepared: • Roller 1 (Fiber roller (wool roller), pile length 25mm) • Roller 2 (Fiber roller (wool roller), pile length 32mm) • Roller 3 (Fiber roller (wool roller), pile length 21mm) • Roller 4 (Fiber roller (wool roller), pile length 13mm)

[0065] (Example 1) Apply primer a (water-based epoxy sealer) at a rate of 100g / m² to a flat slate board. 2 After spray painting the entire surface and allowing it to dry for 24 hours, apply intermediate coating material a (light gray glossy synthetic resin emulsion paint, acrylic resin-based, pigment volume concentration 15%) at a rate of 150g / m². 2 After spray painting the entire surface and letting it dry for 2 hours, apply the intermediate coating material a again at a rate of 150g / m². 2 The entire surface was spray-painted and allowed to dry for 24 hours. By this method, a light gray test substrate a was obtained.

[0066] On the other hand, applying primer a (same as above) to another slate board similar to the one described above at a rate of 100g / m² 2 After spray painting the entire surface and allowing it to dry for 24 hours, apply intermediate coating material b (dark gray glossy synthetic resin emulsion paint, acrylic resin-based, pigment volume concentration 13%) at a rate of 150g / m². 2 After spray painting the entire surface and letting it dry for 2 hours, apply the intermediate coating material b again at a rate of 150g / m². 2The entire surface was spray-painted and allowed to dry for 24 hours. By this method, a dark gray test substrate b was obtained.

[0067] Next, the topcoat material 1 was applied to test substrate a and test substrate b using roller 1 at a rate of 120 g / m². 2 The entire surface was then painted with a roller and allowed to dry for 24 hours. All of the above steps were performed under standard conditions (temperature 23°C, relative humidity 50%).

[0068] The specimens obtained by the above method were visually evaluated for the visibility of the spotted pattern and the finish quality. For visibility, a "○" was used if the spotted pattern was clearly visible in both specimens, and a "×" was used if the spotted pattern was difficult to see in either specimen. For finish quality, specimens in which the spotted pattern was visible were evaluated on a four-point scale (Excellent: A>B>C>D: Poor), with "A" indicating a homogeneous spotted pattern formed by the colored particles, and "D" indicating a finish with noticeable unevenness in the spotted pattern due to the aggregation of colored particles. The results are shown in Table 1. In Example 1, a homogeneous spotted pattern was formed by black particles in test substrate a, and a homogeneous spotted pattern was formed by white particles in test substrate b.

[0069] (Examples 2-9, Comparative Examples 1-2) Except for using the rollers and topcoats listed in Table 1 instead of roller 1 and topcoat 1, test specimens were prepared in the same manner as in Example 1, and the visibility of the spotted pattern and the finish were evaluated. The results are shown in Table 1. In Examples 2 to 9, a homogeneous spotted pattern was formed by black particles on test substrate a, and a homogeneous spotted pattern was formed by white particles on test substrate b. In Comparative Examples 1 and 2, a spotted pattern made of black particles was visible on test substrate a, but the finish was noticeably uneven, and the spotted pattern was difficult to see on test substrate b.

[0070] [Table 1]

[0071] (Example 10) For ceramic siding boards with a brick-like textured surface, apply primer b (water-based epoxy surfacer) at a rate of 200g / m². 2 After spray painting the entire surface and allowing it to dry for 3 hours, apply the intermediate coating material c (black glossy synthetic resin emulsion paint, acrylic silicone resin-based, pigment volume concentration 13%) at a rate of 150g / m². 2 After spray painting the entire surface and letting it dry for 2 hours, apply the intermediate coating material c again at a rate of 150g / m². 2 The entire surface was spray-painted and allowed to dry for 2 hours. Then, the intermediate coating material d (brown glossy synthetic resin emulsion paint, acrylic silicone resin type, pigment volume concentration 14%) was partially applied using a fibrous roller (wool roller, pile length 7 mm) (application amount 60 g / m²). 2 The mixture was dried for 24 hours. By the above method, a test substrate c containing both black and brown was obtained.

[0072] On the other hand, for another ceramic siding board similar to the one described above, primer b (same as above) was applied at a rate of 200g / m². 2 After spray painting the entire surface and allowing it to dry for 3 hours, apply the intermediate coating material e (pale yellow glossy synthetic resin emulsion paint, acrylic silicone resin-based, pigment volume concentration 15%) at a rate of 150g / m². 2 After spray painting the entire surface and letting it dry for 2 hours, apply the intermediate coating material e again at a rate of 150g / m². 2 The entire surface was spray-painted and allowed to dry for 2 hours. Then, a fibrous roller (wool roller, pile length 7mm) was used to partially apply the intermediate coating material f (light brown glossy synthetic resin emulsion paint, acrylic silicone resin type) (application rate 60g / m²). 2 The mixture was dried for 24 hours. By the above method, a test substrate d containing a mixture of pale yellow and pale brown was obtained.

[0073] Next, the topcoat material 8 was applied to test substrate c and test substrate d using roller 1 at a rate of 180 g / m². 2 The entire surface was then painted with a roller and allowed to dry for 24 hours. All of the above steps were performed under standard conditions (temperature 23°C, relative humidity 50%).

[0074] The visibility of the spotted pattern and the finish of the test specimens obtained by the above method were evaluated. The evaluation criteria were as described above. The results are shown in Table 2. In Example 10, a homogeneous spotted pattern was formed mainly by white particles on test substrate c, and a homogeneous spotted pattern was formed mainly by black particles on test substrate d.

[0075] (Examples 11-13) Except for using the rollers and topcoats listed in Table 2 instead of roller 1 and topcoat 8, test specimens were prepared in the same manner as in Example 10, and the visibility of the spotted pattern and the finish were evaluated. The results are shown in Table 2. In Examples 11 to 13, a homogeneous spotted pattern was formed mainly by white particles on test substrate c, and a homogeneous spotted pattern was formed mainly by black particles on test substrate d.

[0076] [Table 2]

Claims

1. A coating forming method for roller coating a topcoat material on a wall surface, As the topcoat material, synthetic resin emulsion (m), and lightweight colored particles (n) having a bulk density of 1.0 g / ml or less and an average particle diameter of 0.01 to 1 mm are essential components, The light-weight coloring particles (n) contain at least two types of light-weight coloring particles having different colors, Use a topcoat material containing 0.1 to 50 parts by weight of the lightweight colored particles (n) relative to 100 parts by weight of the solid content of the synthetic resin emulsion (m). A coating forming method characterized by:

2. 2. The method for forming a coating film according to claim 1, wherein the light-weight colored particles (n) contain at least two types of light-weight colored particles having a brightness difference of 30 or more.

3. 3. The method for forming a coating according to claim 1, wherein the light-weight coloring particles (n) are granular.

4. 4. The method for forming a coating according to claim 1, wherein the roller is a fibrous roller having a bristle length of 10 mm or more.

5. The coating forming method according to any one of claims 1 to 4, characterized in that after applying a primer and / or intermediate coating material to a wall surface, the topcoat material is applied by roller coating.

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