Coating formation method

Abstract

To provide a film formation method for providing a colored coating and a decorative coating in this order which provides a coating surface excellent in finishing property and aesthetics.SOLUTION: There is provided a film formation method for coating a coating material B onto a colored coating (A) and forming a decorative coating (B), wherein the colored coating (A) has infrared reflectivity, the coating material B is a clear coating material containing a resin component and colored particles as essential components, and 0.1-100 pts.wt. of the colored particles is contained with respect to 100 pts.wt. of a solid content of the resin component.SELECTED DRAWING: None

Description

Technical Field

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

Background Art

[0002] Conventionally, decorative coatings having design patterns have been formed on wall surfaces of buildings, civil engineering structures and the like. For example, Patent Document 1 describes a coating method of laminating a sealer layer, a base enamel layer, and a layer made of a clear coating material containing colored aggregates on a substrate. According to the coating method of Patent Document 1, a decorative coating in which grains of colored aggregates are scattered can be formed. However, in the recoated portion of the clear coating material containing such colored aggregates, the density of the colored aggregates may increase, the recoated portion becomes conspicuous, and there is a risk that the finish property is impaired.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] The present invention has been made in view of the above problems, and an object of the present invention is to improve finish properties, aesthetic properties and the like on a film surface having a decorative coating in which colored particles are scattered.

Means for Solving the Problems

[0005] As a result of intensive studies on such problems, the present inventors have conceived a film forming method using a specific film as a base for a decorative coating, and have completed the present invention.

[0006] That is, the present invention has the following features. 1. A method for forming a decorative coating (B) by applying a coating material B to a colored coating (A), The aforementioned colored coating (A) has infrared reflectivity. Furthermore, it contains one or more infrared reflective powders selected from manganese-bismuth composite oxides and iron-chromium composite oxides. The decorative coating (B) has a thickness of 10 to 95 μm. The aforementioned coating material B is a clear coating material containing resin components and colored particles as essential components. The colored particles are flaky colored particles with a short diameter of 0.2 to 5 mm and / or granular lightweight colored particles with a bulk density of 1.0 g / mL or less. The resin component contains 1 to 4.5 parts by weight of the colored particles per 100 parts by weight of solid content. The method for forming a coating is characterized in that the decorative coating (B) forms a spotted pattern in which the colored particles are scattered. [Effects of the Invention]

[0007] According to the method of the present invention, the finish, aesthetics, and other properties can be improved on a coated surface having a decorative coating in which colored particles are scattered. [Modes for carrying out the invention]

[0008] The following describes embodiments for carrying out the present invention.

[0009] The present invention relates to a method for forming a decorative coating (B) by applying a coating material B to a colored coating (A).

[0010] In this invention, the colored coating (A) has infrared reflectivity, which enables the formation of a decorative coating (B) with excellent finish and aesthetic appeal. The mechanism by which this occurs can be considered as follows, for example.

[0011] When coating material B is applied over a colored film (A), it gradually hardens to form a decorative film (B). However, the joint between the applied coatings may become noticeable. This is thought to be related to the hardening properties and conformability of the coating material. In other words, if the coating material applied to a predetermined area first hardens too quickly, it becomes difficult for it to conform with the coating material applied to the adjacent area later, resulting in a noticeable joint. In particular, when applying a speckled pattern with scattered colored particles in a clear film, such as the decorative film (B) of the present invention, overlapping or denser areas of colored particles are likely to occur at the joints, which can result in an uneven appearance at the joint.

[0012] In contrast, the present invention reduces the influence of sunlight and other elements during the formation process of the decorative surface by having the colored coating (A) reflect infrared rays, and allows the hardening of the decorative coating (B) to proceed stably and appropriately. As a result of this action, the adhesion between adjacent coating materials on the coated surface is improved, making it possible to form a patterned surface with excellent finish and aesthetic appeal.

[0013] [Colored film (A)] The colored coating (A) of the present invention is characterized by having infrared reflectivity. Such a colored coating (A) can be formed by applying and drying coating material A. Coating material A preferably contains a resin component and an infrared reflecting powder as essential components.

[0014] Examples of resin components in coating material A include water-soluble resins, water-dispersible resins, solvent-soluble resins, solvent-free resins, non-water-dispersible resins, etc., or composites thereof. These may have crosslinking reactivity, and their form is not particularly limited; they may be one-component or two-component. In the present invention, aqueous resins such as water-dispersible resins (resin emulsions) and water-soluble resins are particularly preferred. Examples of usable resins include acrylic resins, urethane resins, vinyl acetate resins, silicone resins, fluororesins, epoxy resins, acrylic vinyl acetate resins, acrylic urethane resins, acrylic silicone resins, polyester resins, alkyd resins, and vinyl chloride resins, and one or more of these can be used. Among these, acrylic resins, urethane resins, acrylic urethane resins, acrylic silicone resins, and fluororesins are preferred.

[0015] Examples of infrared-reflective powders in coating material A include aluminum flakes, titanium oxide, barium sulfate, zinc oxide, iron oxide, calcium carbonate, silicon oxide, magnesium oxide, zirconium oxide, yttrium oxide, indium oxide, alumina, iron-chromium composite oxide, manganese-bismuth composite oxide, manganese-yttrium composite oxide, 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, etc., and one or more of these can be used.

[0016] The ratio of infrared reflective powder is preferably 3 to 800 parts by weight, more preferably 5 to 600 parts by weight, per 100 parts by weight of solid content of the resin component. In this invention, "α to β" is synonymous with "α or more and β or less".

[0017] The coating material A may further contain infrared transmitting powder. By appropriately combining these infrared transmitting powders, a wide variety of color tones can be expressed. Examples of the infrared transmitting powder include perylene pigments, azo pigments, lead yellow, iron oxide red, vermilion, titanium red, cadmium red, quinacridone red, isoindolinone, benzimidazolone, phthalocyanine green, phthalocyanine blue, cobalt blue, indanthrene blue, ultramarine blue, and Prussian blue, and one or more of these can be used.

[0018] The proportion of the infrared transmitting powder is preferably 1 to 200 parts by weight, more preferably 2 to 100 parts by weight, based on 100 parts by weight of the solid content of the resin component.

[0019] The coating material A may contain powders other than those described above (for example, color pigments, extender pigments, etc.) within a range that does not impair the effects of the present invention. However, the content of infrared absorbing powder such as carbon black is preferably 1% by weight or less, more preferably 0.5% by weight or less, based on the total amount of the powders, and an embodiment containing no infrared absorbing powder is most preferred.

[0020] The coating material A may contain various components other than the above components within a range where the effects of the present invention are not significantly impaired. Examples of such components include matting agents, aggregates, thickeners, film-forming aids, leveling agents, coupling agents, wetting agents, plasticizers, antifreezing agents, pH adjusters, preservatives, antifungal agents, algaecides, antibacterial agents, dispersants, defoamers, adsorbents, fibers, crosslinking agents, ultraviolet absorbers, antioxidants, light stabilizers, catalysts and the like.

[0021] [Decorative coating film (B)] The decorative coating film (B) can be formed by applying and drying the coating material B. The coating material B is characterized as a clear coating material containing a resin component and colored particles as essential components. The decorative coating film (B) formed by such coating material B (clear coating material) is fixed in a state where the colored particles are scattered in the transparent coating film, and the colored particles on the colored coating film (A) are each visually recognized as a pattern (spotted pattern), which can impart excellent aesthetic properties.

[0022] The resin component in coating material B is not limited to any resin that forms a transparent film, and examples include water-soluble resins, water-dispersible resins, solvent-soluble resins, solvent-free resins, non-water-dispersible resins, etc., or composites thereof. These may also have crosslinking reactivity, and their form is not particularly limited; they may be one-component or two-component. In the present invention, aqueous resins such as water-dispersible resins (resin emulsions) and water-soluble resins are particularly preferred. Examples of usable resins include acrylic resins, urethane resins, vinyl acetate resins, silicone resins, fluororesins, epoxy resins, acrylic vinyl acetate resins, acrylic urethane resins, acrylic silicone resins, polyester resins, alkyd resins, vinyl chloride resins, etc., and one or more of these can be used. Among these, acrylic resins, urethane resins, acrylic urethane resins, acrylic silicone resins, and fluororesins are preferred.

[0023] The colored particles in coating material B are not particularly limited as long as they are solid particles having some kind of color, and their material can be either inorganic or organic, and they can be either natural or artificial. Furthermore, the shape of the colored particles is not particularly limited, and for example, they can be flaky or granular. In the present invention, various colored particles (colored particles with different materials, colors, sizes, etc.) can be mixed and used according to the desired design. As the colored particles of the present invention, for example, flaky colored particles can be suitably used.

[0024] Examples of flaky colored particles include inorganic fragments such as mica, sericite, clay, talc, plate-like kaolin, barium sulfate flakes, glass flakes, alumina flakes, shell fragments, and metal fragments, or organic fragments such as rubber fragments, plastic fragments, wood fragments, and plant fragments. Alternatively, these can be used as base particles and then colored. The coloring treatment is not particularly limited, but examples include coating (or adsorbing) the base particles with a coloring agent containing pigments or dyes, or applying a calcination treatment to the base particles. In this invention, it is preferable to use mica (colored mica) that has been coated with a coloring agent.

[0025] In this invention, "flaky" refers to particles whose shape is flaky (thin flake-like), but it is preferable that the aspect ratio (ratio of "short diameter / thickness") is 1.5 to 2000 (more preferably 1.6 to 1000, even more preferably 2 to 500, and particularly preferably 3 to 100). It is also preferable that the ratio of short diameter to long diameter (short diameter / long diameter) is 0.3 to 1 (more preferably 0.4 to 1, even more preferably 0.5 to 1). Furthermore, it is preferable that the short diameter is 0.1 to 10 mm (more preferably 0.15 to 8 mm, even more preferably 0.2 to 5 mm). The "short diameter," "long diameter," and "thickness" referred to herein are calculated by observing the flaky particles stably on a horizontal surface using a microscope from above, with the shortest part length being the "short diameter," the longest part length being the "long diameter," and the maximum height from the bottom surface being the "thickness."

[0026] In this invention, by ensuring that the size of the flake-like particles meets the above range, the flake-like colored particles in the clear coating are clearly visible as patterns (spot patterns), providing excellent aesthetic appeal. Furthermore, it is possible to form a design layer that is excellent in terms of thinning the design layer and reducing its weight. In particular, according to the coating formation method of the present invention, since the colored coating (A) has infrared reflectivity, the hardening of the coating material B is suppressed, making it easier for the flake-like particles to orient along the clear coating, and thus enabling the formation of a coating with even greater aesthetic appeal.

[0027] Examples of granular colored particles include crushed materials such as marble, granite, serpentinite, fluorite, crimson stone, feldspar, silica, and silica sand; inorganic particles such as crushed ceramics, crushed porcelain, crushed ceramics, metal particles, glass beads, and crushed glass; and organic particles such as resin beads (resin particles), crushed resin, rubber particles, wood particles, and plant particles. Colored versions of these particles can also be used. These can be used individually or in combination of two or more types. The coloring treatment is not particularly limited, but examples include coating (or adsorbing) a coloring agent containing pigments or dyes onto the base particles, or applying a firing treatment to the base particles.

[0028] In the present invention, it is preferable to use granular lightweight colored particles (hereinafter also referred to as "lightweight colored particles") among the above-mentioned granular colored particles, which have a bulk density of 1.0 g / mL or less (preferably 0.01 to 0.95 g / mL, preferably 0.2 to 0.8 g / mL). Such lightweight colored particles are less likely to cause unevenness during painting, making it possible to form a uniform spotted pattern. The lightweight colored particles are not particularly limited as long as their bulk density meets the above range, but for example, resin beads (resin particles), crushed resin, rubber granules, wood particles, plant particles, etc., and colored versions thereof are preferred. In the present invention, "bulk density" 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.

[0029] Furthermore, the size of the granular colored particles is preferably such that the average particle diameter is 0.01 mm to 1 mm (more preferably 0.02 mm to 0.5 mm, and more preferably 0.04 mm to 0.3 mm). In this range, the aggregation of granular colored particles within the clear coating is sufficiently suppressed, and the convex shape of the granular colored particles is less noticeable. Each granular colored particle is visible as a pattern (spot pattern), providing excellent aesthetic appeal.

[0030] In this invention, "granular" refers to particles in which the ratio of average particle diameter to average thickness ("average particle diameter / average thickness") is 2 or less (preferably 1.5 or less). The average particle diameter is the average value of the longest axis when the granular colored particles are placed on a horizontal surface in their most stable position and observed from above using a microscope. The average thickness is the average value of the interplanar spacing when the particles, placed on a horizontal surface in their most stable position, are sandwiched between two horizontal surfaces.

[0031] The coating material B of the present invention contains 0.1 to 100 parts by weight (preferably 0.2 to 80 parts by weight, more preferably 0.5 to 50 parts by weight) of the above-mentioned colored particles per 100 parts by weight of solid content of the resin component. Furthermore, when using flake-shaped colored particles and / or granular lightweight colored particles, it is preferable to contain 0.1 to 30 parts by weight (more preferably 0.3 to 20 parts by weight, even more preferably 0.5 to 10 parts by weight, particularly preferably 0.8 parts by weight or more and less than 5 parts by weight, most preferably 1 to 4.5 parts by weight) of the flake-shaped colored particles and / or granular lightweight colored particles per 100 parts by weight of solid content of the resin component. In this range, it is possible to impart a speckled pattern in which the colored particles are scattered in the clear coating, and there is no risk of obscuring the colored coating (A), so that a speckled pattern that makes use of the color of the colored coating (A) can be formed, and the temperature rise of the formed coating can also be suppressed.

[0032] Furthermore, in the present invention, it is preferable that the coating material B contains 0.1 to 20% by weight of colored particles (preferably 0.15 to 10% by weight, more preferably 0.2 to 8% by weight, even more preferably 0.25 to 5% by weight, and particularly preferably 0.3 to 4% by weight). This further enhances the above effects.

[0033] The coating material B (clear coating material) of the present invention has a transparent film, and may be colorless transparent or colored transparent, and may be glossy or matte (including 70% gloss, 50% gloss, 30% gloss, etc.). Such a clear coating material can be mixed with coloring pigments, extender pigments, and other powder components (excluding the above-mentioned coloring particles) to the extent that the transparency of the clear film can be maintained. However, with respect to infrared absorbing powders such as carbon black, the amount is preferably 1% by weight or less, more preferably 0.5% by weight or less, relative to the total amount of powder, and an embodiment that does not contain infrared absorbing powder is most preferable.

[0034] Coating material B may contain various components other than those listed above, as long as the effects of the present invention are not significantly impaired. Examples of such components include thickeners, film-forming aids, leveling agents, coupling agents, wetting agents, plasticizers, antifreeze agents, pH adjusters, preservatives, antifungal agents, antialgal agents, antibacterial agents, dispersants, defoaming agents, adsorbents, fibers, crosslinking agents, ultraviolet absorbers, antioxidants, light stabilizers, catalysts, and the like.

[0035] [Film formation method] The present invention involves forming a decorative coating (B) by applying a coating material B to the surface (preferably the entire surface) of a colored coating (A). The colored coating (A) can be formed by applying the coating material A to a substrate.

[0036] Examples of substrates to which the present invention can be applied include gypsum board, plywood, wallpaper, concrete, mortar, porcelain tile, fiber-reinforced cement board, cement calcium silicate board, slag cement perlite board, ALC board, siding board, extruded board, steel plate, and plastic board. The surfaces of these substrates may have been treated with some kind of surface treatment (e.g., sealer, surfacer, filler, etc.), or they may already have a coating applied, already have wallpaper attached, or have an uneven surface.

[0037] When applying coating material A, known tools such as brushes, rollers, sprayers, and trowels can be appropriately selected and used. The amount of coating material A to be applied is preferably 0.05 to 2 kg / m². 2 (more preferably 0.1~1.5 kg / m 2 )

[0038] The coating material B is applied using tools such as a spray, roller, brush, or trowel, selected as appropriate, so that the thickness of the decorative coating (B) after drying is less than 200 μm (more preferably less than 100 μm, and even more preferably 10 to 95 μm). In the present invention, the above effects can be sufficiently obtained with such a thin film. Multiple tools may be used in combination as needed. The amount of coating material B applied is not particularly limited as long as the decorative coating (B) satisfies the above thickness, but is generally 0.05 to 0.5 kg / m 2 (More preferably 0.08~0.4 kg / m 2 A degree of this is preferable. In such a case, there is no risk of obscuring the colored film (A), and therefore the temperature rise of the formed film can also be suppressed. [Examples]

[0039] The following examples illustrate the features of the present invention.

[0040] The following materials were prepared as covering material A. ○Coating material A1 To 200 parts by weight of synthetic resin emulsion 1 (acrylic resin emulsion, glass transition temperature 20°C, solids content 50% by weight), 20 parts by weight of infrared reflective powder 1 (manganese-bismuth composite oxide) and 10 parts by weight of additives (film-forming aid, thickener, defoamer, etc.) were uniformly mixed by a conventional method to obtain a black coating material A1 with infrared reflective properties.

[0041] ○Coating material A2 To 200 parts by weight of synthetic resin emulsion 1 (same as above), 20 parts by weight of infrared reflective powder 2 (iron-chromium composite oxide) and 10 parts by weight of additives (film-forming aid, thickener, defoamer, etc.) were uniformly mixed by a conventional method to obtain a black coating material A2 with infrared reflective properties.

[0042] ○Coating material A3 To 200 parts by weight of synthetic resin emulsion 1 (same as above), 20 parts by weight of infrared-absorbing powder (carbon black) and 10 parts by weight of additives (film-forming aid, thickener, defoamer, etc.) were uniformly mixed by a conventional method to obtain a black coating material A3 with infrared absorption properties.

[0043] The following materials were prepared as covering material B. ○Coating material B1 200 parts by weight of synthetic resin emulsion 2 (acrylic silicone resin emulsion, glass transition temperature 32°C, solids content 50% by weight) was uniformly mixed with 3 parts by weight of colored mica (gray, average short diameter 3 mm, average aspect ratio 11) and 10 parts by weight of additives (film-forming aid, thickener, defoamer, UV absorber, etc.) by a conventional method.

[0044] ○Coating material B2 200 parts by weight of synthetic resin emulsion 2 (same as above) was uniformly mixed with 4 parts by weight of lightweight colored particles (gray resin particles, bulk density 0.68 g / mL, average particle diameter 0.1 mm, average particle diameter / average thickness = 1.0) and 10 parts by weight of additives (film-forming aid, thickener, defoamer, UV absorber, etc.) by a conventional method.

[0045] (Examples 1, 2, 3; Comparative Examples 1, 2) The following tests were conducted to evaluate the finish quality. The combinations of colored coating (A) and decorative coating (B) are shown in Table 1. (test) For a slate board (900 x 900 mm), apply coating material A at a rate of 0.3 kg / m². 2The material was spray-painted, cured for 6 hours under standard conditions (temperature 23°C, relative humidity 50%), and then heated under a 250W infrared lamp for 3 hours. At this point, the right half was painted with coating material B using a medium-pile roller to achieve a dry film thickness of 80 μm. Three minutes later, the left half was painted with the same coating material B using a medium-pile roller to create an overlap, also achieving a dry film thickness of 80 μm. The finish of the coating surface was then evaluated. The evaluation criteria were as follows: A was assigned to those with no noticeable seams and excellent overall aesthetics of the coating surface, and D was assigned to those with noticeable seams, with a rating of A > B > C > D.

[0046] [Table 1]

Claims

[Claim 1] A method for forming a coating, comprising applying a coating material B to a colored coating (A) to form a decorative coating (B), The aforementioned colored coating (A) has infrared reflectivity and contains one or more infrared reflecting powders selected from manganese-bismuth composite oxide and iron-chromium composite oxide. The decorative coating (B) has a thickness of 10 to 95 μm. The coating material B is a clear coating material containing resin components and colored particles as essential components. The colored particles are flaky colored particles with a short diameter of 0.2 to 5 mm and / or granular lightweight colored particles with a bulk density of 1.0 g / mL or less. The resin component contains 1 to 4.5 parts by weight of the colored particles per 100 parts by weight of solid content. A method for forming a coating, characterized in that the decorative coating (B) forms a spotted pattern in which the colored particles are scattered.

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