JP4711813B2 - Pattern surface formation method - Google Patents

Description

  The present invention relates to a pattern surface forming method capable of creating a novel design. The present invention can be preferably applied particularly to pattern surface formation in internal and external walls and floors of buildings, civil engineering structures, and the like.

  In recent years, with increasing interest in wall surfaces and floor surfaces with aesthetics, pattern surfaces with aesthetics such as natural stone, ceramic tiles, and bricks are widely used. As a method of forming such a pattern surface, for example, after applying a primer that becomes a joint color, a joint material made of a resin foam or the like is applied, and then a finish coating material such as natural stone is applied, There is a method for removing the joint material thereafter. According to this method, the construction period is greatly shortened and the cost can be greatly reduced as compared with the case where natural stones, tiles, bricks, and the like are attached one by one. In addition, it can exhibit aesthetics almost equivalent to natural stone, ceramic tiles, bricks and the like.

For example, in Japanese Patent Laid-Open No. 10-296180 (Patent Document 1), a lower spray layer is sprayed evenly on a base material to which a joint rod is attached, and then an upper spray layer is sprayed so that a part of the lower spray layer is exposed. After that, the method of removing the joint rod and further polishing is described. According to the method of Patent Document 1, it is possible to form an insect-eating pattern surface partitioned by joints.
Japanese Patent Application Laid-Open No. 11-62163 (Patent Document 2) discloses a method for obtaining a natural sandstone-like pattern surface by applying joint tape to a base layer at a predetermined interval to form a transparent or translucent coating in multiple layers. A method for removing joint tape after painting is described.

JP-A-10-296180 JP-A-11-62163

However, in the method as described in the above-mentioned patent document, the hue of the joint portion is usually limited to a single color such as black, gray, etc., and the device for improving the design is exclusively for the shape of the joint portion or the surface pattern other than the joint portion. The dependence was great. In addition, the method of the above-mentioned patent document requires a polishing step and a multilayer coating step, so that the operation becomes complicated and it is difficult to obtain a stable pattern surface.
The present invention has been made in view of the above-described background, and an object of the present invention is to create a novel joint pattern that has not existed in the past by a simple method.

  As a result of diligent studies to achieve the above object, the present invention has come up with a method of using a decorative coating material and a specific peelable joint material in combination, and has completed the present invention.

That is, the present invention has the following characteristics.
1. A method of forming a pattern surface having a joint pattern,
A step (1) of applying a decorative coating material containing a binder and colored powder particles to a substrate;
While the decorative coating material is undried, a part of the surface of the coating film is embedded while pressing a peelable joint material having a smooth bottom surface and air permeability to form a joint pattern. Smoothing process (2),
Step (3) of drying the decorative coating material;
Removing the strippable joint material (4),
A method for forming a pattern surface, comprising:

  ADVANTAGE OF THE INVENTION According to this invention, the novel joint pattern which is not in the past can be created by a simple method.

  Hereinafter, the best mode for carrying out the present invention will be described.

  FIG. 1 is a cross-sectional view showing an example of a specific process in the present invention. An embodiment of the present invention will be described with reference to FIG.

  The present invention is mainly applicable to the inner and outer wall surfaces, floors, etc. of buildings, or the surface of civil engineering structures. The base material 1 is a material that constitutes such a part. For example, concrete, mortar, siding board, extrusion board, gypsum board, perlite board, plywood, plastic board, metal board, wood board, glass, ceramic tile Various base materials, such as these, are mentioned. These base materials 1 are those that have been subjected to some surface treatment (filler treatment, putty treatment, surfacer treatment, sealer treatment, etc.), those that have been coated with some colored paint, those that have already been coated, It may be one with a wallpaper attached.

  As shown in FIG. 1A, in the present invention, a decorative coating material 2 is first applied to the substrate 1 as a step (1). This decorative coating material 2 contains a binder and colored powder as essential components.

  Examples of the binding material in the decorative coating material 2 include acrylic resin, urethane resin, epoxy resin, vinyl acetate resin, silicon resin, fluororesin, acrylic vinyl acetate resin, acrylic urethane resin, acrylic silicon resin, polyvinyl alcohol, and cellulose derivatives. These can be used, and one or more of these can be used. As the synthetic resin, water-based resins such as water-dispersible resins and water-soluble resins are suitable.

The colored powder particles are components that impart various hues to the decorative coating material. In the present invention, it is possible to enhance the versatility of the decorative coating material by using a combination of two or more colored powder particles having different hues. The hue of the colored powder particles may be either an achromatic color or a chromatic color, and may have transparency. Specific examples of the colored powder particles include titanium oxide, zinc oxide, carbon black, black iron oxide, red bean, perylene red, quinacridone red, yellow iron oxide, benzimidazolone yellow, phthalocyanine green, ultramarine blue, bituminous blue, and phthalocyanine. Colored pigments such as blue and quinacridone violet; Heavy pigments such as heavy calcium carbonate, kaolin, clay, diatomaceous earth, talc, precipitated barium sulfate, and silica powder; ground natural stone, ceramic powder, silica sand, ceramic powder, rubber particles, metal Examples thereof include aggregates such as grains and the like, or those obtained by color-coating these surfaces.
The weight ratio of the colored powder particles is usually 100 to 4000 parts by weight, preferably 200 to 2000 parts by weight, and more preferably 300 to 1500 parts by weight with respect to 100 parts by weight of the solid content of the binder.

The method for applying the decorative coating material 2 is not particularly limited, and methods such as spray coating, roller coating, brush coating, and iron coating can be employed. The decorative coating material 2 may be applied to the entire surface of the base material. The application amount of the decorative coating material 2 is usually about 0.5 to 10 kg / m ² .

In the step (2), while the decorative coating material 2 is undried, it is embedded in a part of the coating surface while pressing the peelable joint material 3 having a smooth bottom surface and air permeability ( FIG. 1 (b)). By this step, the portion where the joint pattern is to be formed is smoothed. That is, a glossy feeling and a decorative pattern are imparted to the joints of the pattern surface to be finally formed.
And since the joint material in this invention has air permeability, the decoration coating material 2 can be dried in the state which embedded the joint material (process (3)). That is, since a medium such as water contained in the decorative coating material located under the peelable joint material 3 volatilizes through the peelable joint material 3, the decoration located under the peelable joint material 3. The drying delay of the coating material can be suppressed, and the work period can be shortened. Furthermore, the use of the strippable joint material 3 can prevent the joint groove from being deformed when the joint material is removed, and a joint pattern with high aesthetics can be formed.

  On the other hand, since the fine unevenness resulting from the viscosity of the coating material or the colored powder particles remains on the surface of the coating film other than the joint portion, the finish is less glossy than the surface of the joint portion. In the present invention, an unprecedented aesthetic appearance can be created by providing such a difference in gloss between the joint portion and other portions.

  FIG. 2 is a diagram (sectional view) showing an example of the peelable joint material 3 in the present invention. The peelable joint material 3 in FIG. 2 has a bottom surface 4 and side surfaces 5 rising from both ends of the bottom surface 4. Of these, the bottom surface 4 has a smooth shape and air permeability.

Examples of the air permeable material constituting the bottom surface 4 include sheet materials of water vapor permeable polymer compounds such as polyvinyl acetate, cellulose acetate, and polyvinyl alcohol, and fibrous materials such as woven fabric and nonwoven fabric. Further, a material obtained by binding powder of about 1 to 100 μm with a resin binder in such an amount that a space is generated between the powders can be used as the air-permeable material. In this case, hygroscopic powder can be used as the powder.
Although the material which comprises the side surface 5 is not specifically limited, A breathable material as mentioned above can also be used.
In FIG. 2, the peelable joint material 3 is shown having a cavity inside the joint material, but the joint material is filled with a breathable material unless the effect of the present invention is impaired, A material having a reinforcing material inside the joint material can also be used.

  In this invention, in order to prevent that a joint material becomes impossible to remove by drying of an undried coating film, what has peelability is used as a joint material. In order to impart peelability to the joint material, for example, a method of treating the joint material with a water repellent such as a silicone compound can be employed. It is sufficient to perform this process only on the outer side of the bottom surface of the joint material. However, the processing may be performed on the entire outer peripheral surface of the bottom surface and the side surface.

  In the present invention, air permeability and peelability can also be imparted to the joint material by adopting a breathable water-repellent sheet-like material as the material constituting the bottom surface 4 of the joint material. Examples of such a breathable water-repellent sheet are, for example, JP-A-58-144178, JP-A-60-173178, JP-A-3-167362, JP-A-4-216038, and JP-A-6-6. No. 114991, JP-A-6-200481, JP-A-6-313275, JP-A-7-54274, JP-A-7-279059, JP-A-2001-138425, JP-A-2001-214374 Those described in the publication can be used.

  The bottom surface 4 made of such a material is preferably one that does not deform when the peelable joint material 3 is embedded in the coating film while being pressed (when pressed). However, even if the bottom surface 4 is deformed at the time of pressing, after pressing, the inner side of the bottom surface 4 is leveled using a roller, a spatula, etc. in a state where the peelable joint material 3 is adhered, Smoothing can be performed.

  What is necessary is just to perform the smoothing process by the strippable joint material 3 so that the glossiness of a polishing wind may be acquired in a final joint part. Specifically, it is desirable to perform treatment so that the 85 ° specular glossiness of the joint surface is 5 or more (preferably 10 or more).

  What is necessary is just to determine the position, space | interval, etc. which embed the peelable joint material 3 according to a desired joint pattern, and it may be a uniform space | interval and may be random. Examples of patterns include tile-like patterns, brick-like patterns, geometric patterns, polka dot patterns, striped patterns, lattice patterns, spiral patterns, heraldic patterns, as well as graphic patterns designed for animals, plants, objects, characters, etc. Is possible. In order to express these patterns, a plurality of linear joint materials may be used in combination, or a flat pattern paper punched according to the pattern shape may be used as the joint material.

  In the present invention, when the peelable joint material 3 is embedded while being pressed, the decorative coating material 2 swells around the joint material. The portion where the decorative coating material 2 swells in this way may be leveled with a spatula, a trowel or the like before the coating material is dried, or may be left as it is.

When the swell of the decorative coating material 2 around the joint material is left untreated, the boundary between the joint portion and the other surface coating film becomes clear, and a sharp uneven pattern can be obtained. In order to obtain such an effect, the decorative coating material 2 has a viscosity of 50 to 1500 Pa · s (preferably 100 to 1000 Pa · s, more preferably 200 to 800 Pa · s), and a thixotropy index (TI value) of 3.0. It is desirable to set it above (preferably 4.0 to 8.0, more preferably 5.0 to 7.0). The viscosity mentioned here is the viscosity at 2 rpm (guide value for the second rotation) measured with a BH viscometer at a temperature of 23 ° C., and the TI value is a value obtained from the following formula.
<Formula> TI value = η1 / η2
(In the formula, η1 represents the apparent viscosity at 2 rpm (Pa · s: guide value for the second rotation), and η2 represents the apparent viscosity at 20 rpm (Pa · s: guide value for the fourth rotation). ℃.)

  The width of the peelable joint material 3 is usually about 5 mm or more (preferably 5 to 100 mm), and can be appropriately set within this range. In particular, if the width of the strippable joint material 3 is set to 30 mm or more, the glossiness of the joint part is easily visually recognized. Further, even when such a wide joint material is used, the lower coating material can be sufficiently dried. Furthermore, if a wide joint material is used, the sharpness of the concavo-convex pattern can be further emphasized by the bulge around the joint part. The height of the strippable joint material 3 is usually about 0.5 to 10 mm.

The decorative coating material 2 may be dried (step (3)) to such an extent that the shape of the joint groove is not impaired in the joint material removal in the next step. The drying time of the decorative coating material 2 after pressing the strippable joint material 3 is usually about 12 hours or more (preferably 16 to 48 hours) at room temperature.
Next, as the step (4), the peelable joint material 3 is removed (FIG. 1 (d)). By removing the strippable joint material 3, joint grooves are formed, and a pattern surface having an uneven pattern is obtained.

After the step (4), it is possible to apply a clear paint or the like as necessary. The clear paint is not particularly limited, and examples thereof include acrylic resin-based paints, urethane resin-based paints, acrylic silicon resin-based paints, and fluororesin-based paints. It is also possible to use a colored type clear paint as long as the effect of the present invention is not impaired.
In the application of the clear paint, a known method can be employed, and various methods such as spray coating, roller coating, and brush coating can be employed.
If the clear paint is applied only to the joints, the difference in gloss from the parts other than the joints can be further increased.

  Examples are given below to clarify the features of the present invention.

(Manufacture of decorative coating materials)
As a binder, 200 parts by weight of an acrylic resin emulsion (solid content 50% by weight, minimum film-forming temperature 24 ° C.) was prepared, and a film-forming auxiliary (2,2,4-trimethyl-1,3-pentanediol mono 16 parts by weight of isobutyrate), 1 part by weight of a cellulose-based thickener, 3 parts by weight of a silicone-based antifoaming agent, and a colored aggregate mixture (white: 620 parts by weight of gray: black = 3: 3: 1) were mixed and stirred uniformly by a conventional method to produce a decorative coating material P. The decorative coating material P had a viscosity of 350 Pa · s and a TI value of 5.4.

(Formation of pattern surface)
An epoxy-based primer was applied to a 90 cm × 90 cm slate plate at a coating amount of 0.2 kg / m ² , dried for 2 hours, and then a decorative coating material P was applied at a coating amount of 3 kg / m ² . . Immediately after application of this coating material, a breathable peelable joint form (lattice, width 50 mm, height 2 mm) was embedded in the coating surface while being pressed and smoothed, and left as it was for 24 hours. As the breathable peelable joint mold, one having a cross-sectional structure shown in FIG. 2 and having a bottom surface and a side surface made of a vinyl acetate sheet material treated with a silicone water repellent was used.
Next, when the joint mold was removed, the joint mold was easily removed, and the coating material under the joint mold was sufficiently dried. All the above steps were performed in a standard state (temperature 23 ° C., relative humidity 50%).
By the above method, a grid-like joint pattern having a glossy feeling (85 degree specular gloss of the joint part is 7) is formed on the natural stone-like pattern over the entire surface. A pattern surface with a clear contrast between the surface pattern and the joints could be obtained.

It is a figure (sectional view) showing an example of the present invention. It is a figure (sectional drawing) which shows an example of a peelable joint material.

Explanation of symbols

1: Base material 2: Decorative coating material 3: Strippable joint material 4: Bottom surface 5: Side surface

Claims (1)

A method of forming a pattern surface having a joint pattern,
A step (1) of applying a decorative coating material containing a binder and colored powder particles to a substrate;
While the decorative coating material is undried, a part of the surface of the coating film is embedded while pressing a peelable joint material having a smooth bottom surface and air permeability to form a joint pattern. Smoothing process (2),
Step (3) of drying the decorative coating material;
Removing the strippable joint material (4),
A method for forming a pattern surface, comprising:

Images