JP7466293B2 - Repair material made by mixing two types of materials and repair method - Google Patents

Description

The present invention relates to a repair material used to repair or glue recesses, chips, cracks, holes, etc. in wooden furniture, vessels, picture frames, floors, or walls, and in particular to a repair material that prevents the odor characteristic of organic solvents and is highly safe.

Repair materials used to repair or glue recesses, chips, cracks, holes, etc. in wooden furniture, floors, or walls require the concentration and viscosity to be adjusted by mixing color powder with a solvent to match the color of the area to be repaired.
This type of mixing and adjustment before construction is a highly difficult process that requires the skills, technique, and experience of the contractor.
On the other hand, in recent years, there has been increasing concern about indoor repairs, such as the carcinogenicity of repair materials when exposed to low concentrations in the general environment after repair work, and the irritation to the human body caused by the emission of volatile substances contained in the repair materials.
The present inventor is primarily developing a new color powder and a new solvent that has high affinity with the color powder in order to prevent sick house syndrome and to carry out repair work using repair materials that do not contain carcinogenic substances.
The present inventors then decided to use inorganic pigments as the main component of the color powder.

Next, the inventor started to develop a solvent that has high affinity with the color powder. As a result, the inventor learned that some organic solvents contained in solvents currently on the market are the cause of sick house syndrome and carcinogens, and he struggled to find a combination of solvents that does not contain such organic solvents and has high affinity with the color powder.
It is also possible that the organic matter contained in organic solvents acts as nutrients for the growth and proliferation of mold. Such dust and mold not only ruin the beauty of the interior and the appearance of furniture, but they have also been linked to allergies and sick house syndrome.
In addition, due to recent climate change, the temperature and humidity in Japan have become more pronounced, causing major changes in the growth and damage caused by mold. As a result, problems such as allergies, sick house syndrome, and fungal infections caused by dust and mold are becoming increasingly serious.
In addition, alcohol-based solvents are less effective at preventing stains and mold. In other words, the main component, alcohol, is highly volatile, so the effect lasts for a short period of time, and there is a drawback in that the environment becomes one in which mold grows soon after the repair agent is applied. In addition, when Japanese cypress is used as the wood, it is known that the unique texture of Japanese cypress is lost when a repair material containing alcohol as the main component is used.

As a result, we came up with the idea of using water-based urethane instead of the solvent currently used to dissolve the color powder, and actually conducted repair experiments on site.
However, water-based urethane has a strong milky white or yellowish brown color when in liquid form, and during the curing period after repair, it reacts with moisture in the air and hardens, changing from translucent to almost colorless and transparent.
Therefore, there is no problem with the construction itself when using water-based urethane for repairs, but a problem became apparent during the construction preparation stage, which is the stage at which you need to consider the color of the surrounding area and the repair material before construction begins, and decide the ratio of color powder to be mixed with the solvent.
In this case, conventional oil-based and water-based solvents have a milky white or yellowish brown color, and discolor after hardening, so it is difficult to match the color of the surrounding area to be repaired in liquid form, and it has been found that a certain amount of experience and skill is required. Also, depending on external factors such as humidity in the air and exposure to ultraviolet rays, it does not necessarily become colorless and transparent to a certain extent, and there is a possibility that a milky white or yellowish brown color will remain in some areas.

Currently, the following methods are mainly known for adjusting the gloss after applying the repair agent.
In this method, pieces of flooring or the like are surrounded by masking tape, a gloss-adjusting liquid is applied, and the masking tape is peeled off after drying. However, when the method of surrounding the pieces with masking tape is adopted, since a water-based urethane or water-based wax containing a gloss-adjusting agent can be applied, the work can be carried out without using carcinogenic organic solvents, but the boundary between the gloss-adjusted and non-gloss-adjusted parts is often clear. In addition, when an organic solvent is included, there is a pungent odor peculiar to the organic solvent, and there is concern about its effects on the human body, such as carcinogenicity. Furthermore, when a water-based material is included, it is known that the particles of the sprayed mist are coarse, and as a result, magnesium carbonate as an additive for gloss adjustment is often sprayed in the form of white granules, which often adheres to the repaired part as white dots.

JP 2013-53500 A Patent No. 6085357

The present invention aims to provide a repair material that can suppress the carcinogenicity caused by low-concentration exposure in the general environment and suppress irritation to the human body caused by the emission of volatile substances contained in the repair material.
The objective of the present invention is to provide a repair material that can significantly reduce the technique, skill, and experience required by the installer in the mixing process of the repair material before construction.
An object of the present invention is to provide a repair material comprising a combination of a first material and a second material that melt completely together.
Furthermore, the present invention aims to provide a method of adjusting gloss by a simple method without using masking tape, using a water-based material (first material, etc.) that is not carcinogenic while maintaining a natural texture that makes the repaired area less noticeable, and which can be expected to produce a finish that is comparable to the good finish produced by conventional organic solvent (lacquer-based) spray cans.

In order to solve the above problems, the present inventors have adopted a repair material having the following configuration.
(1) The present invention is a repair material composed of a first material and a second material, characterized in that the first material is an aqueous urethane resin composition containing at least polyurethane, an organic solvent, and an aqueous medium, and having transparency due to its low milky white color, and the second material is composed of a colored powder mainly composed of at least crushed iron oxide. This repair material is composed of two types of materials mixed together.
The present invention relates to a repair material manufactured by mixing at least two kinds of materials. Any repair material obtained by mixing materials other than the above two kinds of materials, as long as it has the effect of the repair material composed of the above composition of the present invention, falls within the technical scope of the present invention.
The first material here is, for example, an aqueous urethane resin composition obtained by mixing polyurethane, an alcohol-based solvent, water, and an additive.
The polyurethane constituting the first material of the present invention is a liquid urethane resin having urethane bonds in the main chain.
Currently, most repair materials are organic solvent-based, but the present invention is characterized by the selection of a water-based material with excellent coating performance.

Examples of the organic solvent constituting the first material of the present invention include those mainly composed of acetone, isobutyl alcohol, isopropyl alcohol, isopentyl alcohol, ethyl ether, ethylene glycol monoethyl ether, ethylene glycol monoethyl ether acetate, ethylene glycol mono-n-butyl ether, ethylene glycol monomethyl ether, ortho-dichlorobenzene, xylene, cresol, corbenzan, isobutyl acetate, isopropyl acetate, ethyl acetate, n-butyl acetate, etc. Of course, those mainly composed of materials other than those mentioned above are also included as long as they can be suitably used as organic solvents for repair materials.
The aqueous medium used in the present invention mainly means a compound of hydrogen and oxygen, but also includes heavy water and water containing impurities in the broad sense, so long as it is colorless and transparent.
Furthermore, it is essential that the first material of the present invention has transparency due to a low milky white color. Solvents containing urethane resins for general repair materials currently on the market have a milky white color.

In the present invention, a transparent material refers to a material with a transparency of more than 6 mm. The transparency defined here is a value measured by gradually filling a beaker with a diameter of 100 mm and a height of 80 mm with a sample solution for measuring the transparency. The beaker is placed on a sign paper printed with a tree pattern. In this state, the empty beaker is gradually filled with the sample solution, and the water depth in mm at which the tree pattern on the sign paper cannot be distinguished by visual inspection is the transparency in the present invention. The first material used in the present invention must have a transparency of more than 6 mm.

The second material of the present invention is a colored powder obtained by pulverizing iron oxide obtained by oxidizing metallic iron with oxygen. Here, the iron oxide may be produced by any method as long as it can be used as a pigment. For example, there are natural iron oxides, so-called loess, sienna, which is made from natural soil containing hydrated iron oxide as the main component and silicic acid colloid and a small amount of manganese, ochre, which has hydrated iron oxide as the main color-developing component, and umber, which contains manganese dioxide.
The coloring materials currently used in repair materials are mainly paste-like materials such as paint. However, paste-like materials have a short shelf life and harden over time even when the lid is on, making it difficult to reuse them. Once opened, the deterioration period tends to be even shorter.
The second material used in the present invention is a colored powder obtained by crushing iron oxide, and therefore has the effect of being semi-permanently storable. In addition, since the first material and the second material can be stored completely separately, the mixing ratio of the first material and the second material can be adjusted according to the color of the repaired area, and the hiding power of the paint can be manipulated.
Furthermore, since the second material used in the present invention is made by crushing iron oxide into a powder, it is free of impurities that would inhibit its melting with the first material used in the present invention, and therefore has the advantages of being highly pure as an inorganic pigment and having excellent melting properties in an aqueous urethane resin composition. For example, when a coloring material manufactured by Mohawk is mixed with the first material used in the present invention, it may not melt completely and may leave behind ball-like residues.

(2) The present invention is a repair material obtained by mixing the two types of materials described in (1) above, characterized in that the mixing ratio of the first material and the second material is 20% by weight to 70% by weight:30% by weight to 80% by weight.
If the mixing ratio of the second material exceeds 80% by weight, the solid content remains in the repair material, and it becomes a muddy paste-like state and loses fluidity, making it difficult to apply to the repaired area. On the other hand, the mixing ratio of the second material loses its function as a paint, making it difficult to apply to the repaired area, making it difficult to exert its effect as a repair agent.

(3) The present invention relates to a repair method for repairing recesses, chips, cracks, and holes in wooden furniture, vessels, picture frames, floors, or walls using a repair material, the method comprising at least a floating step and a coloring step, wherein in the floating step, a first material made of an aqueous urethane resin composition having transparency due to a low milky white color is coated on the area to be repaired to form a coating film, and then in the coloring step, a repair material refined by mixing the first material made of an aqueous urethane resin composition containing at least polyurethane, an organic solvent, and an aqueous medium and having transparency due to a low milky white color with a second material mainly composed of at least a colored powder obtained by crushing iron oxide is applied and then dried.
(4) The present invention is a repair method as described in (3) above, characterized in that it includes a pretreatment step in the repair method, in which a filler having an epoxy resin is filled into the recessed portion on the repair area having a missing portion.

(5) The present invention is a repair method as described in (3) or (4) above, characterized in that after applying the repair material in the repair method, a gloss adjustment process is performed in which a first material is sprayed in a mist form onto the area to be repaired.
Here, the method of spraying the first material in a mist form includes a method of spraying the first material on the repaired area using a painting tool called an airbrush. By using such a gloss adjustment process, gloss adjustment that is comparable to the finish of conventional organic solvent can spray gloss adjusters can be performed more easily. For example, by adopting the gloss adjustment process of the present invention, there is no need to surround flooring, etc. with masking tape, and further, since the first material is sprayed in a mist form using air, it is possible to naturally blur the boundaries and apply a coating to the area.
By adopting the repair method of the present invention, it is possible to achieve a high-quality finish using non-carcinogenic water-based materials, and high-quality repairs can be completed without using carcinogenic organic solvents in the entire process. In particular, even if a gloss-adjusting spray can is simply used, the additive may adhere to the relevant area as a white substance, and a high-quality result may not be obtained. Furthermore, when using an organic solvent (lacquer-based) spray can, it is difficult to eliminate the carcinogenic material and the irritating odor is strong, making it difficult to achieve the effects of the present invention.

The repair material according to the present invention has the effect of suppressing the carcinogenicity caused by the repair material when exposed to low concentrations in the general environment, and suppressing irritation symptoms on the human body caused by the emission of volatile substances contained in the repair material.
The repair material of the present invention has the excellent effect of suppressing discoloration of materials before and after repair, thereby significantly reducing the technique, skill, and experience required by the installer in the mixing process of the repair material before construction.
Furthermore, the present invention has the excellent effect of providing a repair material that can be easily adapted to a variety of repair situations because it is composed of a first material and a second material that melt completely together.
Furthermore, the present invention has the excellent effect of providing a method that makes it possible to adjust gloss by a simple method without using masking tape, and that uses a water-based material (first material) that is not carcinogenic, while maintaining a natural texture that makes the repair area less noticeable, and that can be expected to produce a finish that is comparable to the good finish achieved with conventional organic solvent (lacquer-based) spray cans.

An example of an embodiment of the present invention will be described below. The embodiment described below is merely an example of the present invention, and is not intended to limit the present invention.
EMBODIMENT 1
The repair agent according to the first embodiment of the present invention is formed by mixing the following first material and second material.
(1) First material: Urethane resin: 33.1% by weight
Alcohol-based solvent: 1.8% by weight
Water: 63.6% by weight
Additives: 1.5% by weight
The first material used in the first embodiment has transparency due to its low milky white color. The transparency was 50 mm.
Incidentally, the urethane resin (manufactured by Mohawk) currently used as an organic solvent in repair materials has a transparency of 6.0 mm.

(2) Secondary material: White pigment: titanium oxide; Red pigment: vermilion; Blue material: Prussian blue; and 36 other color powders.

By mixing the 36 color powders and aniline listed above, it is possible to reproduce the colors of almost any wooden floor or furniture.
Determine the color of the floor or furniture to be repaired, and prepare a color powder that matches the color of the floor or furniture to be repaired in a paint tray. Mix 50% by weight of the first material and 50% by weight of the second material. The preferred mixing ratio of the first material and the second material is first material:second material=20-70% by weight:30-80% by weight.
Two or more types of color powder may be mixed together to match the color of the area to be repaired.
The repair agent of the present invention has a high transparency of the first material, so it can be easily adjusted to match the color of the repaired part. In other words, if a conventional first material with a transparency of 6.0 mm and a strong milky white color is used, the milky white color of the first material becomes cloudy when color powder is mixed in, making it difficult to mix the intended color after drying.
On the other hand, the first material of this embodiment has a transparency of 50 mm and is therefore highly transparent, so that it is easy to predict the color that will ultimately be obtained when mixing the color powder. Therefore, by using the repair agent according to this embodiment 1, discoloration of the mixed material before and after drying can be suppressed, and an excellent effect is recognized in that the technique, skill, and experience of the installer can be significantly reduced in the mixing process of the repair material before construction.

EMBODIMENT 2
The repair method according to the present invention was used to repair scratches on a floor (flooring).
Step 1
First, select a two-liquid epoxy resin putty as the filler _{, and} thoroughly knead the base agent and hardener in your hands. When the base agent and hardener are mixed together, a chemical reaction begins, causing hardening in about 10-20 minutes.
Fill the recesses in the flooring before the resin begins to harden. Make sure the resin has hardened sufficiently.

Step 2
Sandpaper is then used to further smooth out the recessed areas.
Prepare 240-grit sandpaper and wrap it around a "grinding plate." Use a piece of wood or similar as the grinding plate. Use the sandpaper to remove the dents and make them flatter.

Step 3
Next comes the process of restoring the color to the recessed areas.
Currently, the dents and scratches have been filled with putty to make them flat.
The main tools and materials needed for staining wood are as follows:
・First material with transparency due to low milky white color Polyurethane resin 33% by weight
Alcohol-based solvent 2% by weight
Water 63% by weight
Additives 2% by weight
・Second ingredient: Carafe color powder Carafe aniline liquid (synthetic dye additive liquid)
・Nonwoven fabric (cloth diapers)
・Flat brush ・Water

(1) Floating Floating is a process carried out prior to coloring, and is an optional process that can be carried out between colorings. The surface of the colored coating is not smooth, so it scatters light. As a result, the color appears whiter than its actual color due to the effect of the scatter.
For this purpose, water-based urethane is impregnated into nonwoven fabric and applied to the colored coating surface. This process forms a new coating film on top of the first colored coating film. As a result, the coating surface becomes smooth, diffuse reflection of light is suppressed, and the actual color is visualized.
Next, fold a 15cm x 15cm non-woven fabric, soak it in the first material, and apply it to the putty and the area around the putty. This will remove the whitish color. After that, repeat this floating process several times while drying with a hair dryer.

(2) Coloring: The first and second materials are mixed in a paint tray.
The secondary material is available in 36 different colors, and by mixing these 36 types of powder or aniline, it is possible to reproduce the color of almost any wooden floor or furniture.
In the second ingredient, if you add more liquid to the amount of powder, the hiding power of the color can be weakened, while if you increase the ratio of powder, the hiding power will be stronger.
Take an arbitrary amount of the second material from the paint tray and apply it over the putty with a brush.
Next, the area where the second material has been applied is floated.
After floating, color adjustments can be made. For example, lighter or darker powder can be dissolved and applied on top with a flat or face brush.
Once the colors have matched to a certain extent, the next step is to use a face brush to reproduce the wood grain.
(3) Coating Paint There are three main types of first material: glossy, semi-glossy, and matte. A coating paint is applied to adjust the gloss over the colored areas of the first material.

The following description will be given taking as an example a case where the area to be repaired is flooring.
Example 1
When adjusting the gloss of flooring, the gloss is adjusted taking into account the pieces of the flooring (the breaks between the boards).
First, surround the flooring pieces with masking tape. Second, wrap nonwoven fabric (diaper cloth) around the abrasive board in about three layers, soak the nonwoven fabric in liquid, and then apply the liquid to the pieces. There are three types of liquid available: gloss, extra matte (matte), and silk matte (semi-gloss). Select the one that matches the gloss of the flooring and apply it accordingly.
For example, it is possible to mix gloss and silk matte liquids. It is also possible to apply gloss and dry it, then apply silk matte on top. Choose the appropriate color to match the gloss of the surrounding area.
You can apply multiple layers of liquid repeatedly until you achieve a good finish.

Example 2
Organic solvent (lacquer-based) spray-on gloss adjusters have been widely used in the past and are known to be highly effective in adjusting gloss, but by spraying the first material onto the area to be repaired using a painting tool known as an airbrush, it is possible to achieve gloss adjustment that is comparable to the finish achieved by conventional organic solvent spray-on gloss adjusters.
The difference from Example 1 above is that there is no need to surround the pieces with masking tape on the flooring.
That is, the first material is sprayed in a mist form by air, so that the boundary between the first material and the coating can be applied to the corresponding area while naturally blurring the boundary. The coating method of Example 2 is also useful for wooden furniture.
This gloss adjustment method makes it possible to complete all repair processes without using organic solvents.

Claims (3)

A repair method for repairing recesses, chips, cracks, and holes in wooden furniture, vessels, picture frames, floors, or walls using a repair material, which includes at least a floating step and a coloring step, and in the floating step, a first material made of an aqueous urethane resin composition containing at least polyurethane, an organic solvent, and an aqueous medium, and having transparency due to a low milky color, is applied to the repaired area to form a coating film, and in the coloring step, a repair material refined by mixing the first material made of an aqueous urethane resin composition containing at least polyurethane, an organic solvent, and an aqueous medium, and having transparency due to a low milky color, with a second material mainly composed of colored powder obtained by crushing at least iron oxide is applied and then dried. 2. The repair method according to claim 1 , further comprising a pretreatment step of filling a recessed portion of a repaired portion having a chipped portion with a filler having an epoxy resin. 3. A repair method according to claim 1 , further comprising a gloss adjustment step of spraying a first material in a mist form onto the area to be repaired after the application of the repair material in the repair method.