Method for forming a coating film on a metal powder surface

Abstract

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

Description

Technical Field

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[0001] The present invention relates to a method for forming a metal powder-exposed coating film. law It relates to the above.

Background Art

[0002] Paints containing metal powder provide a unique metallic luster to the painted surface when applied, presenting an aesthetic appearance. Also, paints containing metal powder have the advantage of being excellent in weather resistance and the like.

[0003] In such paints containing metal powder, they are generally used in a dispersed state so that the metal powder component does not precipitate with respect to the liquid component (see, for example, Patent Document 1). That is, a dispersant is added so that the metal powder is well dispersed in the paint, or a curing agent is used in a large amount so that the paint cures before the metal powder component precipitates after the paint is applied.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] However, the inventors have succeeded in increasing the density of the metal powder by deliberately precipitating the metal powder in the paint, forming a so-called metal powder layer in the paint film, and exposing the metal powder layer as the outermost layer to form a paint film with strong metallic luster and unprecedented design properties.

[0006] Therefore, an object of the present invention is to provide a method for forming a metal powder-exposed coating film that can obtain a suitable metallic texture. law It aims to provide the above.

Means for Solving the Problems

[0007] The present invention is a method for forming a metal powder-exposed coating film, comprising: a painting step of applying a metal powder-containing coating to a surface to be painted; a metal powder sedimentation step, after the painting step, of drying the metal powder-containing coating to form a metal powder-containing coating film on the surface to be painted and settling the metal powder contained in the applied metal powder-containing coating film; and a metal powder layer formation step, after the metal powder sedimentation step, of polishing the surface of the metal powder-containing coating film to expose the metal powder within the coating film, thereby forming a metal powder layer on the outermost layer. Furthermore, the present invention relates to a member with a metal powder-exposing coating, comprising a member to be painted including a surface to be painted, and a metal powder-exposing coating formed on the surface to be painted, wherein the metal powder-exposing coating is formed when a metal powder-containing paint is applied to the surface to be painted, the metal powder-containing paint dries and forms a metal powder-containing coating on the surface to be painted, the metal powder contained in the applied metal powder-containing paint settles, and the surface of the metal powder-containing coating is polished to expose the metal powder within the metal powder-containing coating, thereby forming a metal powder layer on the outermost layer. Furthermore, the present invention relates to a metal powder exposure coating film formed on a surface to be painted of a member to be painted, including the surface to be painted, characterized in that a metal powder-containing paint is applied to the surface to be painted, the metal powder-containing paint dries to form a metal powder-containing coating film on the surface to be painted, the metal powder contained in the applied metal powder-containing paint settles, the surface of the metal powder-containing coating film is polished to expose the metal powder within the metal powder-containing coating film, and a metal powder layer is formed as the outermost layer.

[0008] In this configuration, a metal powder layer is formed by deliberately allowing the metal powder to settle, thereby adequately protecting the surface to be painted, and then the metal powder layer can be exposed to produce a strong metallic luster.

[0009] Furthermore, in the above invention, the metal powder-containing paint may also contain an unsaturated polyester, styrene, a thixotropy modifier, a surfactant, and a curing agent. Furthermore, the member with the metal powder exposure coating comprises a member to be painted, including a surface to be painted, and a metal powder exposure coating formed on the surface to be painted. The metal powder exposure coating is characterized in that, when a metal powder-containing paint is applied to the surface to be painted and a metal powder-containing coating is formed on the surface to be painted, the metal powder contained in the metal powder-containing paint settles, and the surface of the metal powder-containing coating is polished, causing the metal powder within the metal powder-containing coating to be exposed, thereby forming a metal powder layer on the outermost layer. In addition, the metal powder exposure coating is formed when the metal powder-containing paint is applied to the surface to be painted. The present invention is characterized in that, when a metal powder-containing coating film is formed on the surface to be painted, the metal powder contained in the metal powder-containing coating settles, and the surface of the metal powder-containing coating film is polished, exposing the metal powder within the coating film, thereby forming a metal powder layer on the outermost layer. Furthermore, the metal powder may be a powder of a predetermined metal material. Furthermore, the metal powder may contain powders of two or more metals. [Effects of the Invention]

[0010] This invention has the excellent effect of providing a desirable metallic texture that is unprecedented. [Brief explanation of the drawing]

[0011] [Figure 1] This is an explanatory diagram showing the state in which a metal powder-containing paint has been applied to the component to be painted according to the example. [Figure 2] This is an explanatory diagram showing the state in which the metal powder-containing paint according to the example is dried to form a metal powder layer. [Figure 3] This is an explanatory diagram showing the state in which the metal powder layer according to the embodiment is exposed. [Modes for carrying out the invention]

[0012] The following describes the method for forming a metal powder coating film according to the present invention. law The present invention will be described in detail in the following embodiment. It should be noted that the present invention is not limited to the embodiments shown below, and design modifications can be made as appropriate.

[0013] [Formation of Metal Powder Exposed Coating Film] The method for forming a metal powder exposed coating film will be described in order below.

[0014] [Coating Process] As shown in Fig. 1, a metal powder-containing paint 20 is applied to the coating target surface 11 of the coating target member 10 as a building material for interior or exterior materials. At this time, the metal powder 21 in the metal powder-containing paint 20 is dispersed and randomly present in the metal powder-containing paint 20.

[0015] [Metal Powder Precipitation Process] By allowing a time for the metal powder-containing paint 20 applied to the coating target surface 11 in the coating process to dry, as shown in Fig. 2, the metal powder 21 precipitates to form a metal powder layer 30 adjacent to the coating target surface 11. At this time, the outermost layer, the surface layer 40, becomes a resin layer containing almost no metal powder.

[0016] [Metal Powder Layer Formation Process] Next, by polishing the surface layer 40, as shown in Fig. 3, the metal powder layer 30 is exposed to form a metal powder exposed coating film 50, and the coating target member 10 is made into a member 60 with a metal powder exposed coating film.

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

[0018] [Unsaturated Polyester] Unsaturated polyester is the main liquid component of the metal powder-containing paint. It is preferable to add 80 to 70 parts by mass of unsaturated polyester.

[0019] [Styrene] Styrene is added to the unsaturated polyester to promote curing and adjust the viscosity. It is preferable to add 20 to 30 parts by mass of the styrene monomer.

[0020] [Hardener] The curing agent is used to cure liquid unsaturated polyester. It is preferable to add 0.5 to 3 parts by mass of the curing agent. In some cases, a curing accelerator such as cobalt naphthenate may be added.

[0021] [Surfactants] By adding a surfactant, a suitable separation effect between the liquid component and the metal powder in the metal powder-containing paint after application can be obtained. Examples of surfactants include anionic surfactants, cationic surfactants, amphoteric surfactants, and nonionic surfactants. Here, it is preferable to add 0.1 to 2 parts by mass of surfactant. If the amount is less than 0.1 parts by mass, a good separation effect of the surfactant cannot be obtained. If the amount is more than 2 parts by mass, the effect of the surfactant will saturate within the paint component, and the excess surfactant will be wasted.

[0022] [Thixotropic modifier] By adding a thixotropic modifier, a suitable dispersion effect of metal powders in liquids such as unsaturated polyesters in the paint before application can be obtained. Possible thixotropic modifiers include polyhydroxycarboxylic acid amides and polyhydroxycarboxylic acid esters. Preferably, the thixotropic modifier is added in an amount of 0.1 to 3 parts by mass. If the amount is less than 0.1 parts by mass, a good dispersion effect of the thixotropic modifier cannot be obtained. If the amount is more than 3 parts by mass, the effect of the thixotropic modifier will saturate within the paint components, and the excess thixotropic modifier will be wasted.

[0023] [Metal powder] The metal powder can be any metal that can be powdered, such as iron, copper, brass, bronze, aluminum, stainless steel, zinc, or tin; there are no particular limitations on the type of metal that can be used. Furthermore, by blending multiple types of metal powders, it is possible to obtain metallic properties that resemble those of an alloy in terms of design. In addition, the density of the resulting metal powder coating can be freely designed. For example, it is preferable to add 100 to 300 parts by mass of metal powder.

[0024] Next, we will explain the method for preparing the paint. However, a viscosity cup NK-2 (manufactured by Anest Iwata Corporation) was used to measure viscosity (unit: seconds).

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

[0026] [Adjustment method] After adding a surfactant, styrene monomer, and thixotropy modifier to an unsaturated polyester binder and stirring, metal powder is added and the mixture is stirred further.

[0027] The viscosity of a mixture containing metal powder is measured.

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

[0029] After letting it stand at 60°C for 30 to 60 minutes, check for hardening. Then, wipe the painted surface with thinner until the gloss of the paint film is gone. Next, sand the painted surface (gradually from #220 grit to #5000 grit) and check the appearance again.

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

[0031] 10. Components to be painted 11 Surfaces to be painted 20 Paint containing metal powder 21 Metal powder 30 Metal powder layer 40 Surface layer 50 Metal powder exposed coating film 60 Metal powder exposed coating material

Claims

1. A painting process in which a metal powder-containing paint, comprising metal powder, unsaturated polyester, styrene, a curing agent, a surfactant for separating the liquid component and metal powder in the metal powder-containing paint after application, and a thixotropy modifier for dispersing the metal powder in the unsaturated polyester liquid in the paint before application, is applied to a surface to be painted. After the painting step, a metal powder sedimentation step is performed in which the metal powder containing the paint is dried to form a metal powder containing film on the surface to be painted, and the metal powder contained in the applied metal powder containing paint is sedimented. After the metal powder precipitation step, a metal powder layer formation step is performed, in which the surface of the metal powder-containing coating film is polished to expose the metal powder within the coating film, thereby forming a metal powder layer on the outermost layer. A method for forming a metal powder coating film, characterized by including the following:

2. The metal powder is obtained by pulverizing a predetermined metal material. The method for forming a metal powder coating film according to claim 1.

3. The metal powder comprises two or more metal powders. A method for forming a metal powder coating film according to claim 1 or claim 2.

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