Film formation method

Abstract

To provide a coat formation method for securely applying a homogenous dotted pattern by roller coating on an existing wall surface at a construction site, etc.SOLUTION: The invention is a coat formation method by applying a coating material by roller coating at least after applying an intermediate coating material on a wall surface. Synthetic resin emulsion (m) and light-weight coloring particle (n) having bulk density of 1.0 g / ml or less and average particle diameter of 0.01 to 1 mm are essential components of the coating material. The coating material containing 0.1 to 50 parts by weight of the light-weight coloring particle (n) is used for a solid content of 100 parts by weight of the synthetic resin emulsion (m). Glossiness is different between a coat of the intermediate coating material and a coat of the coating material.SELECTED DRAWING: None

Description

Technical Field

[0001] The present invention relates to a novel film-forming method.

Background Art

[0002] Conventionally, as materials constituting the wall surface of a building, inorganic building materials such as siding boards and ALC boards have been widely used. In the painting of such inorganic building materials, in order to enhance their design properties, techniques such as attaching a speckled pattern to the surface have been adopted. For example, Patent Document 1 describes a method of forming a speckled pattern by spray painting while controlling the pattern, discharge amount, etc. during painting using a colored paint prepared to a specific viscosity. Further, Patent Document 2 describes a method of unevenly applying a colored paint of a color different from that of the base paint after applying the base paint.

[0003] However, all of these techniques relate to painting methods in a factory, and a speckled pattern is formed by sputter painting while mechanically controlling the colored paint. For inorganic building materials installed as wall materials at a construction site, since deterioration progresses over time, repainting is required. However, even if an attempt is made to apply the techniques of the above-mentioned patent documents to painting at such a construction site, it is difficult to stably obtain a speckled pattern of a desired size, and the current situation lacks practicality.

[0004] On the other hand, a method of attaching a speckled pattern by applying a top coat in which aggregates such as silica sand and mica are dispersed in a resin liquid to an inorganic building material is also known. According to such a method, a speckled pattern of a desired size can be obtained by setting the particle size of the aggregate to be used. For example, Patent Document 3 describes a method of applying a clear top coat containing a flat colored substance such as mica on a laminated multicolor pattern coating film.

Prior Art Documents

Patent Documents

[0005]

Patent Document 1

[0006] However, in the painting of a topcoat containing aggregates such as silica sand and mica as described above, when a roller is used as a painting tool, the aggregates tend to gather on the painted surface, and there is a risk of unevenness in the speckled pattern, making it difficult to obtain a uniform speckled pattern.

[0007] Further, Patent Document 3 describes, as a specific example of a topcoat, a matte-type topcoat containing colored mica, extender pigments, etc., and it is described that after applying a matte base paint, the topcoat is applied. However, in such a painting method, when a non-painted area (an area where the topcoat is not applied) of the topcoat occurs, it is difficult to identify the area, and there is a risk that subsequent repair will also be difficult.

[0008] The present invention has been made in view of the above problems, and an object thereof is to provide a film-forming method for surely applying a uniform speckled pattern by roller painting to an existing wall surface at a construction site or the like. [Means for Solving the Problems]

[0009] As a result of intensive studies to achieve the above object, the present inventor has conceived a method of roller painting a specific topcoat containing lightweight colored particles having a specific bulk density and particle diameter as an essential component after applying at least a specific primer to a wall surface, and has completed the present invention.

[0010] That is, the present invention has the following features. 1. A film-forming method in which a topcoat is roller-painted after applying at least a primer to a wall surface, 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, and 0.1 to 50 parts by weight of the lightweight colored particles (n) are contained per 100 parts by weight of the solid content of the synthetic resin emulsion (m). The film of the intermediate coat material and the film of the topcoat material have different gloss degrees. A film forming method characterized by this. 2. The film forming method according to 1, wherein the lightweight colored particles (n) are granular. 3. The above roller A roller for painting The film forming method according to 1 or 2, characterized in that a fibrous roller with a nap length of 10 mm or more is used.

Effect of the Invention

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

Brief Description of the Drawings

[0012]

Figure 1

Modes for Carrying Out the Invention

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

[0014] The surface to be painted in the present invention is an existing wall surface existing as a building, civil engineering structure, etc. Examples of the base material constituting the wall surface include, for example, 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 film on the surface thereof. The present invention can be preferably applied particularly to an existing wall surface composed of inorganic building materials such as siding boards and ALC boards. When the wall surface is composed of a plurality of inorganic building materials, the joints between the inorganic building materials may be filled with joint materials such as sealing materials and dry joints.

[0015] In the present invention, after applying an undercoat material to the wall surface as described above as necessary, a middle coat material can be applied, and then a top coat material can be applied.

[0016] Among these, as the undercoat material, for example, those having at least one function selected from adhesion, water permeability resistance, base material reinforcement, concealment, base adjustment, base following, etc. can be used. Examples of such undercoat materials include fillers, surfacers, sealers, primers, etc. In the present invention, one or more undercoat materials can be used as necessary.

[0017] As the middle coat material, for example, those having color development properties can be used. By using such a middle coat material, a desired color can be imparted to the surface to be painted before applying the top coat material. The middle coat material may further have at least one function selected from, for example, weather resistance, durability, heat insulation, concealment, waterproofness, etc. When the middle coat material has sufficient performance such as adhesion to the surface to be painted, etc., the application of the undercoat material is not essential.

[0018] As the intermediate coating material, for example, those containing a binder and a coloring pigment can be used. Examples of the binder 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, or composite resins thereof. These can be used alone or in combination of two or more. As such a binder, for example, aqueous resins such as water-dispersible resin (resin emulsion) and water-soluble resin can be preferably used. The glass transition temperature (value obtained from FOX's calculation formula) of the binder is preferably 60°C or lower, more preferably -50 to 50°C. In the present invention, "α to β" is synonymous with "α or more and β or less".

[0019] Examples of the coloring pigment include titanium oxide, 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 lead), molybdate orange, permanent red, permanent carmine, anthraquinone red, perylene red, quinacridone red, yellow iron oxide, titanium yellow, fast yellow, benzimidazolone yellow, chrome green, cobalt green, phthalocyanine green, ultramarine, navy blue, cobalt blue, phthalocyanine blue, quinacridone violet, dioxazine violet, aluminum pigment, pearl pigment, etc. These can be used alone or in combination of two or more. By appropriately using one or more of these coloring pigments, the color tone of the intermediate coating film can be adjusted. The average particle diameter of the coloring pigment is preferably 2 μm or less, more preferably 0.01 to 1 μm. The average particle diameter of the coloring pigment is the average value measured using a laser diffraction particle size distribution measuring device (measurement temperature: 25°C).

[0020] In addition to the above-mentioned components, the intermediate coating material may contain, for example, extender pigments, dyes, aggregates, color particles, matting agents, thickeners, wetting agents, leveling agents, antifreezing agents, film-forming aids, preservatives, fungicides, algicides, antibacterial agents, dispersants, surfactants, defoaming agents, ultraviolet absorbers, light stabilizers, antioxidants, adhesion promoters, low-pollution agents, hydrophilic agents, water-repellent agents, crosslinking agents, curing agents, curing accelerators, plasticizers, coupling agents, adsorbents, pH adjusters, catalysts, water, solvents, etc. The intermediate coating material can be manufactured by uniformly mixing such components by a conventional method.

[0021] The pigment volume concentration (PVC) of the intermediate coating material is preferably 50% or less, more preferably 30% or less, still more preferably 3 to 25%, and particularly preferably 5 to 20%. The use of such an intermediate coating material acts advantageously in terms of substrate followability (such as followability to a wall surface having a joint part filled with a sealing material, etc.) and the ability to achieve a finish that makes use of the texture of the surface to be coated. Furthermore, it is also possible to set a high gloss level for the intermediate coating film. The pigment volume concentration is the volume percentage of the pigment contained in the dry film and is a value obtained by calculation from the mixing amounts of the resin and the pigment constituting the intermediate coating material. The specific gravity of the resin is assumed to be 1.

[0022] Known methods can be adopted for the coating of the intermediate coating material. As the coating method, for example, spray coating, roller coating, brush coating, etc. are possible. In the case of roller coating, a fibrous roller can preferably be used. The coating amount of the intermediate coating material is preferably 0.05 to 0.8 kg / m 2 and more preferably 0.1 to 0.6 kg / m 2 . At the time of coating, a diluent such as water can be mixed to appropriately adjust the viscosity. The drying of the intermediate coating material is preferably carried out at room temperature (0 to 40°C). When the intermediate coating material is coated, the top coating material can be coated after the intermediate coating film is dried.

[0023] In the painting of the intermediate coating material, the entire wall surface can be painted with one type (one color) of intermediate coating material, or painting can be carried out using two or more types of intermediate coating materials with different color tones. In the latter case, for example, after painting the entire surface to be coated with the first intermediate coating material, the second intermediate coating material (a different color from the first intermediate coating material) is partially painted, or the first intermediate coating material and the second intermediate coating material are applied separately to predetermined areas, etc., so that a multicolor pattern in which two or more colors are mixed can be formed. In the present invention, by such painting of the intermediate coating material, while imparting a desired color to the surface to be coated, it is also possible to finish while making use of the texture of the surface to be coated.

[0024] Examples of the intermediate coating film include forms such as having gloss and matte (including 70% gloss, 50% gloss, 30% gloss, etc.). Such an intermediate coating film is selected according to the relationship with the glossiness of the top coating film described later. The matte intermediate coating film can be formed by an intermediate coating material containing a matting agent such as a extender pigment, similar to the top coating material described later.

[0025] In the present invention, the top coating material is roller-coated on the wall surface as described above. The top coating material in the present invention contains a synthetic resin emulsion (m) and specific lightweight colored particles (n) as essential components. In the present invention, by roller-coating such a specific top coating material, it is possible to form a uniform speckled pattern. The final finished appearance is such that a speckled pattern by the lightweight colored particles (n) is added to the background color (the color of the surface to be coated before top coating. When the intermediate coating material is painted, the color of the intermediate coating film), and excellent designability is exhibited.

[0026] Among the components constituting the topcoat material, the synthetic resin emulsion (m) (hereinafter also referred to as the "(m) component") acts as a binder. As the (m) component, those that form a transparent film can be used. Specifically, as the (m) component, for example, 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, etc. can be mentioned. Among these, from the viewpoints of weather resistance, etc., acrylic resin emulsion, urethane resin emulsion, acrylic silicone resin emulsion, fluororesin emulsion, etc., or composite resin emulsions thereof, etc. are preferable. These (m) components can be used singly or in two or more kinds, and two or more kinds of (m) components can also be mixed. The (m) component may have crosslinking reactivity.

[0027] (m) component can be produced, for example, by a single-stage or multi-stage (two-stage, or three or more stages) emulsion polymerization method, etc. When multi-stage emulsion polymerization is adopted, for example, a multi-layer structured emulsion (core-shell type emulsion, etc.) can be obtained.

[0028] The average particle diameter of the (m) component is preferably 30 to 500 nm, more preferably 50 to 300 nm. When the topcoat material contains the (m) component having such an average particle diameter, the topcoat material to be applied is likely to have a milky white appearance, and the topcoat material film immediately after coating (before drying) will also exhibit milky white, which is advantageously effective in suppressing the remaining coating of the topcoat material. Incidentally, the average particle diameter of the (m) component can be measured using a dynamic light scattering measuring device (measurement temperature 25 °C). Also, the glass transition temperature of the resin constituting the (m) component is preferably -30 to 80 °C, more preferably -20 to 60 °C. The glass transition temperature can be obtained by Fox's calculation formula.

[0029] As the lightweight colored particles (n) (hereinafter also referred to as the "(n) component") in the topcoat material, those 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 the (n) component, one or more lightweight colored particles satisfying such conditions can be used.

[0030] The bulk density of the (n) component 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 the (n) component is within the above range, it becomes possible to form a uniform mottled pattern, which is also suitable in terms of coating workability and the like. When the bulk density of the (n) component exceeds the above upper limit value, the particles are likely to gather on the surface to be coated during roller coating, and there is a risk of unevenness in the mottled pattern. The bulk density in the present invention is a value measured by supplying the lightweight colored particles into a cylindrical container and applying vertical vibration (tapping vibration) until the change in the bulk of the lightweight colored particles in the container ends.

[0031] The average particle diameter of the (n) component 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 diameter of the (n) component is within the above range, it becomes possible to form a uniform mottled pattern, which is also suitable in terms of coating workability and the like. When the average particle diameter of the (n) component is smaller than the above lower limit value, it becomes difficult to recognize the mottled pattern on the finished surface after coating. When the average particle diameter of the (n) component is larger than the above upper limit value, the aggregation of the particles and the convex shape of the particles become prominent, which is disadvantageous in terms of finish, aesthetics, etc. There is also a possibility that the coating workability may decrease.

[0032] (n) The shape of the component is not particularly limited, but in the present invention, a granular shape is preferred. The term "granular" as used herein refers to a shape in which the average particle diameter and the average thickness show approximate values. Specifically, as the (n) component, those having a ratio of the average particle diameter to the average thickness (average particle diameter / average thickness) of 2 or less (preferably 1.5 or less) are preferred. Using such a shape is more suitable in terms of homogenizing the mottled pattern and can enhance the aesthetic appearance of the formed film.

[0033] The average particle diameter of the (n) component is the average value of the major axis when observing the particles placed on a horizontal plane in the most stable posture from above. The average thickness is the average value of the surface interval when the particles placed on a horizontal plane in the most stable posture are sandwiched between horizontal planes.

[0034] As the (n) component in the topcoat material, it is desirable to include those having a different color from the background color before the topcoat material is applied. Thereby, the mottled pattern due to the (n) component can be sufficiently visually recognized on the finished surface after coating. When two or more types of primer coats are used for painting before applying the topcoat material, the color tone of the (n) component may be different from at least one of the primer coat films.

[0035] In the present invention, "different color" means those whose mutual color tones can be recognized as different colors by visual inspection. The color difference (ΔE) is preferably 5 or more, more preferably 10 or more, and even more preferably 20 or more. The color difference (ΔE) is a value calculated based on the L * value, a * value, and b * value. For particles such as the (n) component, the measurement is performed on the surface covered with a PE film (colorless and transparent) after placing the particles on a glass plate until the glass surface is covered.

[0036] (n) component can be, for example, those based on rubber, resin, mineral, wood, plant, etc. Among them, organic particles based on rubber or resin are particularly preferred. Such (n) component is not particularly limited in its internal structure as long as its bulk specific gravity, average particle size, etc. satisfy the above conditions. Examples include solid bodies, foams, porous bodies, etc. The color tone of the (n) component may be, for example, the original color tone of the matrix as it is, or it can also be imparted by applying a coloring treatment etc. (for example, coloring treatment inside the matrix, colored coating on the surface of the matrix) to the matrix.

[0037] The mixing amount of the (n) component is 0.1 to 50 parts by weight, preferably 0.5 to 30 parts by weight, more preferably 1 to 20 parts by weight with respect to 100 parts by weight of the solid content of the (m) component. When the mixing amount of the (n) component is within such a range, it becomes possible to form a highly aesthetic homogeneous speckled pattern with spots imparted to the background color. When the mixing amount of the (n) component exceeds the above upper limit value, unevenness is likely to occur in the speckled pattern, and the background color of the lower layer is likely to be hidden, which is disadvantageous in terms of forming the speckled pattern. When the mixing amount of the (n) component is less than the above lower limit value, it becomes difficult to recognize the speckled pattern on the finished surface after painting.

[0038] The topcoat may contain at least one kind (one color) of lightweight coloring particles, or may contain two or more kinds of lightweight coloring particles with different color tones.

[0039] The topcoat may contain, within a range that does not inhibit the effects of the present invention, for example, coloring pigments, extender pigments, dyes, matting agents, thickeners, wetting agents, leveling agents, antifreezing agents, film-forming aids, preservatives, fungicides, algicides, antibacterial agents, dispersants, surfactants, defoaming agents, ultraviolet absorbers, light stabilizers, antioxidants, adhesion-imparting agents, low-pollution agents, hydrophilic agents, water-repellent agents, crosslinking agents, curing agents, curing accelerators, plasticizers, coupling agents, adsorbents, pH adjusters, catalysts, water, solvents, etc. The topcoat can be manufactured by uniformly mixing such components by a conventional method.

[0040] The heating residue of the topcoat material is preferably 10 to 80% by weight, more preferably 20 to 60% by weight, and even more preferably 30 to 55% by weight. The heating residue can be measured according to the method of "heating residue" in JIS K5601-1-2 (heating temperature: 135 °C, heating time: 60 minutes).

[0041] The film formed by the topcoat material has component (n) scattered in the transparent film, exhibiting a mottled pattern. That is, it has transparency that allows the background color before topcoat application to be visible. The transparent film formed by the topcoat material may be either colorless and transparent or colored and transparent. Among these, the colored and transparent film can be formed by a topcoat material containing, for example, a colored pigment, a dye, etc., and the degree of coloring may be set within a range where the background color and the mottled pattern are visible.

[0042] Examples of the film formed by the topcoat material (topcoat film) include forms such as having gloss, matte finish (including 70% gloss, 50% gloss, 30% gloss, etc.). Such a topcoat film is selected according to the relationship with the glossiness of the intermediate coat film. Among these, the matte topcoat film can be formed by a topcoat material containing a matting agent such as a extender pigment. It is also possible to obtain a matte topcoat film by using a topcoat material in which two or more resins are compounded. When the topcoat material contains a matting agent, the glossiness can be set by adjusting the type, ratio, etc. of the matting agent.

[0043] As the matting agent, for example, extender pigments and the like can be used. Specifically, heavy calcium carbonate, light calcium carbonate, clay, kaolin, talc, barium carbonate, white carbon, diatomaceous earth, gypsum, pottery clay, china clay, barite powder, barium sulfate, precipitated barium sulfate, silica sand, silica powder, quartz powder, resin powder, resin beads, glass beads, hollow balloons, zeolite, sodium sulfate, alumina, allophane, vermiculite, perlite, otsuishi powder, activated clay, shirasu balloons and the like can be mentioned. These can be used alone or in combination of two or more. As the extender pigment, uncolored products without coloring treatment can be used. In particular, as the extender pigment, those having a refractive index of 1.4 to 1.7 are preferably used. By using such an extender pigment, it is possible to enhance the matting effect while maintaining the transparency of the film. The refractive index can be measured using an Abbe refractometer. Further, the average particle diameter of the extender pigment is preferably 100 μm or less, more preferably 1 to 60 μm, and still more preferably 2 to 40 μm from the viewpoints of the transparency, texture, matting effect, etc. of the film. The average particle diameter of the extender pigment is the average value measured using a laser diffraction particle size distribution measuring device (measurement temperature: 25°C).

[0044] When the topcoat material contains an extender pigment, the mixing amount of the extender pigment depends on the degree of matting, but is preferably 10 to 200 parts by weight, and preferably 20 to 120 parts by weight, based on 100 parts by weight of the solid content of the component (m).

[0045] The topcoat material of the present invention is different from materials such as multicolor pattern paints (multicolor paints) and stone-like finish topcoat materials (stone-like paints). Generally, multicolor pattern paints contain liquid or gel-like color particles at a high ratio, and form multicolor patterns by these color particles, and stone-like finish topcoat materials contain colored aggregates and natural aggregates at a high ratio, and exhibit a stone-like texture by the coloring of these aggregates. On the other hand, the topcoat material of the present invention forms a mottled pattern in which lightweight colored particles (n) are scattered due to the above-described configuration. The main color is exhibited by the background color.

[0046] In the present invention, the intermediate coat film and the top coat film shall have different gloss levels. That is, as the intermediate coat and the top coat, those with different gloss levels of their films are used. In the present invention, by using an intermediate coat and a top coat that satisfy such conditions, even when a missed coating area of the top coat occurs, the area can be easily identified, and repair of the area becomes easier. The gloss level difference between the intermediate coat film and the top coat film is preferably 5 or more, more preferably 15 or more, still more preferably 30 or more, particularly preferably 45 or more, and most preferably 60 or more.

[0047] Note that the gloss level in the present invention is a value measured in accordance with JIS K5600-4-7 "Specular gloss". Specifically, it is the average value of the 60-degree specular gloss measured using a gloss meter after applying a sample to a flat base material (a transparent glass plate for the intermediate coat and a black acrylic plate for the top coat) using a film applicator with a gap of 150 μm and drying it for 48 hours under standard conditions (temperature 23°C, relative humidity 50%).

[0048] Examples of such a combination of the intermediate coat and the top coat include cases where the intermediate coat film has a low gloss level and the top coat film has a high gloss level (the top coat film has a higher gloss level than the intermediate coat film), and cases where the intermediate coat film has a high gloss level and the top coat film has a low gloss level (the top coat film has a lower gloss level than the intermediate coat film). Among these, the latter case is suitable in terms of obtaining a high-quality and aesthetic finish and enhancing the substrate followability. In the latter case, for example, the intermediate coat film can be in a form with a sheen, and the top coat film can be in a matte form.

[0049] When two or more types of intermediate coats are used for painting, it is desirable that each intermediate coat film and top coat film satisfy the above-mentioned conditions.

[0050] In the present invention, a topcoat is applied using a roller. In the present invention, such roller coating can suppress the scattering of the topcoat and improve the coatability of the topcoat on the surface to be coated. As the roller, for example, a fibrous roller, a porous roller, etc. can be used. Among these, in the present invention, a fibrous roller is preferable.

[0051] In the present invention, it is desirable to perform roller coating of the topcoat using a fibrous roller having a pile length of 10 mm or more. Thereby, it becomes possible to form an even more uniform mottled pattern. Such an effect is considered to be achieved by the long fibers of the fibrous roller sufficiently promoting the dispersion of these lightweight coloring particles (n) during roller coating.

[0052] An example of such a roller is shown in FIG. 1. The roller in FIG. 1 is a fibrous roller and has a fibrous layer on the outer surface of a cylindrical core material. The cylindrical core material is hollow so that a handle having a shaft can be attached, and the handle can be attached to the hollow and used. As the cylindrical core material, for example, a core material made of plastic, wood, metal, paper, etc. can be used. Also, in order to improve the mountability between the shaft of the handle and the core material, a mounting auxiliary material or the like can be provided between the shaft of the handle and the core material. 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.

[0053] The pile length of the fibrous roller is preferably 10 mm or more, more preferably 12 mm or more, still more preferably 15 to 40 mm, particularly preferably 18 to 38 mm, and most preferably 20 to 36 mm. Note that the pile length is the length of the fibers constituting the fibrous roller. Specifically, the pile length can be obtained by lightly pinching the fibers of the fibrous roller in the dry state with a finger, pulling them outward from the core material, measuring the length of the fibers, and calculating the average value. A fibrous roller having such a pile length is even more advantageous in terms of forming a uniform mottled pattern.

[0054] Examples of the material of the fibers constituting the fibrous layer include, for example, pig hair, horse hair, goat hair, wool, raccoon dog hair, human hair, silk, cotton, etc., or synthetic fibers such as acrylic fiber, polyurethane fiber, polyester fiber, polypropylene fiber, etc. The fibrous layer can be formed by knitting or weaving such an aggregate of fibers (for example, cotton-like pile, thread-like pile, etc.).

[0055] When applying the topcoat material using such a fibrous roller, the viscosity of the topcoat material can be appropriately set. The topcoat material to be used for coating can be diluted with water or the like as necessary. The viscosity (during coating) of the topcoat material is preferably 0.1 to 15 Pa·s, more preferably 0.3 to 13 Pa·s. The thixotropy index (during coating) of the topcoat material is preferably 6 or less, more preferably 1 to 5. The viscosity is a value obtained by measuring the viscosity (pointer value at the fourth rotation) at 20 rpm using a BH-type viscometer. The thixotropy index (TI) is a value obtained by using a BH-type viscometer and calculated by the following formula. In both cases, the measurement temperature is 23°C. <Formula> TI = η1 / η2 (In the formula, η1 is the viscosity at 2 rpm (Pa·s: pointer value at the second rotation). η2 is the viscosity at 20 rpm (Pa·s: pointer value at the fourth rotation))

[0056] The topcoat material in the present invention can be applied to the entire wall surface. The coating amount of the topcoat material is preferably 50 g / m 2 or more, more preferably 100 to 500 g / m 2 and even more preferably 105 to 400 g / m 2 . The number of coating times of the topcoat material is preferably 1 to 2 times, more preferably 1 time. By applying the topcoat material 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.

[0057] Drying after applying the topcoat material may preferably be performed at normal temperature (0 to 40°C). The drying time is preferably 1 hour or more, preferably about 2 to 24 hours.

[0058] In the present invention, after the topcoat is dried, by visually checking its appearance, it is possible to easily determine the presence or absence of missed coating of the topcoat. When a missed coating area occurs, repair can be performed on that area. In the repair, the topcoat from the previous process may be used to coat the missed coating area. At the time of repair, for example, a brush, a roller, etc. can be used. As the roller, the same fibrous roller as described above can be used.

[0059] In the present invention, by the film-forming method as described above, the aesthetic property of an existing wall surface at a construction site or the like can be enhanced. The present invention is suitable for performing such wall surface renovation (refitting). By applying the film-forming method of the present invention to a wall surface deteriorated over time, the aesthetic property 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 portion 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 portion.

Example

[0060] 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.

[0061] As the topcoat, the following were prepared. · Topcoat 1 To 200 parts by weight of synthetic resin emulsion a (acrylic-silicone resin emulsion, solid content 50% by weight, glass transition temperature 32°C, average particle diameter 110 nm), 4 parts by weight of lightweight colored particles a (black resin particles, bulk density 0.68 g / ml, average particle diameter 0.1 mm, average particle diameter / average thickness = 1.0), 12 parts by weight of a film-forming auxiliary, 50 parts by weight of a matting agent a (colorless resin particles, refractive index 1.5, average particle diameter 15 μm), 1 part by weight of an ultraviolet absorber, 2 parts by weight of a viscosity modifier, and 3 parts by weight of an antifoaming agent were mixed, and further water was mixed and adjusted to a heating residue of 40% by weight to obtain topcoat 1. The 60-degree specular gloss of this topcoat 1 was 3.

[0062] · Topcoat 2 To 200 parts by weight of synthetic resin emulsion b (acrylic resin emulsion, solid content 50% by weight, glass transition temperature 34°C, average particle diameter 150 nm), 8 parts by weight of lightweight colored particles b (black resin particles, bulk density 0.68 g / ml, average particle diameter 0.08 mm, average particle diameter / average thickness = 1.0), 12 parts by weight of a film-forming auxiliary, 54 parts by weight of a matting agent b (colorless resin particles, refractive index 1.5, average particle diameter 8 μm), 2 parts by weight of a viscosity modifier, and 3 parts by weight of an antifoaming agent were mixed, and further water was mixed and adjusted to a heating residue of 45% by weight to obtain topcoat 2. The 60-degree specular gloss of this topcoat 2 was 2.

[0063] · Topcoat 3 To 200 parts by weight of synthetic resin emulsion c (acrylic-silicone resin emulsion, solid content 50% by weight, glass transition temperature 38°C, average particle diameter 100 nm), 2 parts by weight of lightweight colored particles c (black resin particles, bulk density 0.69 g / ml, average particle diameter 0.15 mm, average particle diameter / average thickness = 1.0), 12 parts by weight of a film-forming auxiliary, 47 parts by weight of a matting agent a (same as above), 1 part by weight of an ultraviolet absorber, 2 parts by weight of a viscosity modifier, and 3 parts by weight of an antifoaming agent were mixed, and further water was mixed and adjusted to a heating residue of 42% by weight to obtain topcoat 3. The 60-degree specular gloss of this topcoat 3 was 4.

[0064] · Topcoat 4 In the above topcoat material 1, a topcoat material 4 was obtained in the same manner as the topcoat material 1, except that the mixing amount of the lightweight colored particles a was 12 parts by weight. The 60-degree specular gloss of this topcoat material 4 was 3.

[0065] · Topcoat material 5 In the above topcoat material 1, a topcoat material 5 was obtained in the same manner as the topcoat material 1, except that the mixing amount of the lightweight colored particles a was 32 parts by weight. The 60-degree specular gloss of this topcoat material 5 was 3.

[0066] · Topcoat material 6 To 200 parts by weight of the synthetic resin emulsion a (the same as above), 4 parts by weight of the lightweight colored particles a (the same as above), 12 parts by weight of a film-forming aid, 1 part by weight of an ultraviolet absorber, 2 parts by weight of a viscosity modifier, and 3 parts by weight of an antifoaming agent were mixed, and further water was mixed and adjusted to a heating residue of 40% by weight to obtain a topcoat material 6. The 60-degree specular gloss of this topcoat material 6 was 85.

[0067] · Topcoat material 7 In the above topcoat material 6, a topcoat material 7 was obtained in the same manner as the topcoat material 6, except that 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) was mixed in place of the lightweight colored particles a. The 60-degree specular gloss of this topcoat material 7 was 85.

[0068] · Topcoat material 8 In the above topcoat material 6, a topcoat material 8 was obtained in the same manner as the topcoat material 6, except that 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) was mixed in place of the lightweight colored particles a. The 60-degree specular gloss of this topcoat material 8 was 85.

[0069] As the primer coat materials, the following were prepared. · Primer coat material 1 (light gray acrylic resin emulsion paint, pigment volume concentration 13%, 60-degree specular gloss 85) · Primer coat material 2 (light gray acrylic resin emulsion paint, pigment volume concentration 16%, 60-degree specular gloss 50) · Intermediate coating material 3 (light gray acrylic resin emulsion paint, pigment volume concentration 19%, 60-degree specular gloss 32)

[0070] As rollers, the following were prepared. · Roller 1 (fiber roller (wool roller), pile length 25 mm) · Roller 2 (fiber roller (wool roller), pile length 32 mm) · Roller 3 (fiber roller (wool roller), pile length 21 mm) · Roller 4 (fiber roller (wool roller), pile length 13 mm)

[0071] (Example 1) For a ceramic siding board having a brick-like uneven pattern, an undercoating material a (aqueous epoxy-based sealer) was spray-coated on the entire surface at an application rate of 100 g / m 2 and dried for 3 hours. Then, intermediate coating material 1 was spray-coated on the entire surface at an application rate of 150 g / m 2 and dried for 2 hours. After that, intermediate coating material 1 was spray-coated on the entire surface again at an application rate of 150 g / m 2 and dried for 24 hours. Masking seals with a diameter of 8 mm were attached one by one at about 10 cm 3 intervals on the surface of this intermediate coating film. Next, topcoating material 1 was roller-coated on the entire surface at an application rate of 150 g / m 2 using roller 1 and dried for 24 hours, and then the masking seals were removed. All of the above steps were carried out under standard conditions (temperature 23°C, relative humidity 50%). The color difference between the black resin particles and intermediate coating material 1 was 52.

[0072] For the specimens obtained by the above method, the masking discriminability and the finishability were visually evaluated. The evaluation criteria for the masking discriminability (denoted as "discriminability" in the table) were evaluated in four grades (excellent: A > B > C > D: poor), where those with the masking part being easily distinguishable were rated as "A" and those with difficulty in distinguishing the masking part were rated as "D". The evaluation criteria for the finishability were also evaluated in four grades (excellent: A > B > C > D: poor), where those with a homogeneous speckled pattern formed by the coloring particles were rated as "A" and those with a finish where the coloring particles aggregated and the deviation of the speckled pattern was prominent were rated as "D". The results are shown in Table 1.

[0073] (Examples 2 to 11, Comparative Examples 1 to 3) Specimens were prepared in the same manner as in Example 1, except that the intermediate coating material, roller, and top coating material described in Table 1 were used instead of Intermediate Coating Material 1, Roller 1, and Top Coating Material 1, respectively, and the masking discriminability and the finishability were evaluated. The results are shown in Table 1.

[0074]

Table 1

Claims

1. A film-forming method in which at least an intermediate coating material is applied to a wall surface and then a top coating material is applied by roller coating, comprising: as the top coating material, a 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, and 0.1 to 50 parts by weight of the lightweight colored particles (n) are contained per 100 parts by weight of the solid content of the synthetic resin emulsion (m); a top coating material is used, the film of the intermediate coating material and the film of the top coating material have different gloss degrees A film-forming method characterized by the above.

2. The film-forming method according to claim 1, wherein the lightweight colored particles (n) are granular.

3. The film-forming method according to claim 1 or 2, wherein a fibrous roller having a pile length of 10 mm or more is used as the roller for performing the roller coating.

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