JP7731227B2 - Film formation method - Google Patents

Description

The present invention relates to a novel coating formation method.

Traditionally, inorganic building materials such as siding boards and ALC panels have been widely used as materials for constructing the walls of buildings. When painting such inorganic building materials, techniques such as applying a speckled pattern to the surface have been adopted to enhance their design. For example, Patent Document 1 describes a method of forming a speckled pattern by spray-painting a colored coating material prepared to a specific viscosity while controlling the pattern and amount dispensed during painting. Patent Document 2 also describes a method of applying a base coating material and then unevenly applying a colored coating material of a different color from the base coating material.

However, all of these techniques involve painting methods performed in factories, in which the speckled pattern is created by mechanically controlling the application of colored paint and sputtering. Inorganic building materials installed as wall materials at construction sites deteriorate over time, making them necessary to be repainted. However, even if the techniques described in the above patent documents are applied to painting at such construction sites, it is difficult to consistently achieve speckled patterns of the desired size, making them impractical at present.

On the other hand, there is also a known method of applying a speckled pattern to inorganic building materials by applying a topcoat made of aggregates such as silica sand or mica dispersed in a resin liquid. This method allows for the desired size of speckled pattern to be obtained by setting the particle size of the aggregate used. For example, Patent Document 3 describes a method of applying a clear topcoat containing flat coloring matter such as mica over a multicolored multilayered pattern coating.

Japanese Patent Application Publication No. 3-186381 Japanese Utility Model Application Laid-Open Publication No. 4-77440 Patent No. 6180678

However, when using a roller as a painting tool to apply a topcoat containing aggregates such as silica sand or mica, as described above, the aggregates tend to clump together on the surface being painted, which can result in unevenness in the speckled pattern, making it difficult to achieve a uniform speckled pattern.

The present invention was developed in consideration of the above-mentioned problems, and aims to provide a coating formation method that uses roller painting to create a uniform speckled pattern on existing wall surfaces at construction sites, etc.

As a result of extensive research into achieving the above objective, the inventor came up with the idea of a method of applying a specific topcoat material, the essential component of which is lightweight colored particles with a specific bulk density and particle size, to a wall surface using a specific roller, and thus completed the present invention.

That is, the present invention has the following features.
1. A coating formation method in which a topcoat material is roller-coated on a wall surface,
As the topcoat material, synthetic resin emulsion (m), and bulk density is 1.0 g / ml or less, average particle diameter is 0.01 to 1 mm, average particle diameter and average thickness ratio is 1.0 to 1.5 granular lightweight colored particles (n) are essential components, and the synthetic resin emulsion (m) solids 100 parts by weight, the granular lightweight colored particles (n) are used to contain 0.1 to 50 parts by weight of the topcoat material,
A coating forming method characterized in that a fibrous roller having a bristle length of 18 to 38 mm is used as the roller .
2. The coating forming method according to 1., characterized in that after applying a primer and/or intermediate coating material to the wall surface, the topcoat material is applied by roller coating.

According to the present invention, a uniform speckled pattern can be formed on existing wall surfaces at construction sites, etc., by applying paint with a roller, making it easy to obtain a highly aesthetically pleasing finish.

FIG. 2 is a diagram showing an example of a fibrous roller.

The following describes how to implement the present invention.

The coating surface to be coated in this invention is an existing wall surface of a building, civil engineering structure, etc. Examples of substrates that make up the wall surface include concrete, mortar, cement board, extruded molding 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, hardwood cement board, PVC extruded siding board, plywood, etc., as well as materials having a coating film on their surface. The present invention is particularly applicable to existing wall surfaces made of inorganic building materials such as siding board and ALC board. When a wall surface is made up of multiple inorganic building materials, the joints between the inorganic building materials may be filled with a joint material such as a sealant or dry joint material.

In the present invention, a primer and/or intermediate coat can be applied to the wall surface described above before the top coat is applied.

Among these, the primer can have at least one function selected from adhesion, water resistance, substrate reinforcement, hiding power, base adjustment, and base conformability. Examples of such primers include fillers, surfacers, sealers, and primers. In the present invention, one or more types of primers can be used as needed.

The intermediate coating material can be, for example, one that has color-developing properties. By using such an intermediate coating material, the desired color can be imparted to the surface before the top coat is applied. The intermediate coating material may also have at least one function selected from, for example, weather resistance, durability, heat insulation, hiding power, waterproofing, etc. If the intermediate coating material has sufficient performance, such as adhesion to the surface, the application of a primer is not necessary.

The intermediate coating material may contain, for example, a binder and a color pigment. Examples of binders 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, and composite resins of these. These may be used alone or in combination of two or more. Preferred binders include water-based resins such as water-dispersible resins (resin emulsions) and water-soluble resins. The glass transition temperature of the binder (the value calculated using the FOX formula) is preferably 60°C or lower, more preferably -50 to 50°C. In this specification, "α to β" is synonymous with "α or higher and β or lower."

Examples of color pigments 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 oxide), 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 blue, Prussian blue, cobalt blue, phthalocyanine blue, quinacridone violet, dioxazine violet, aluminum pigments, and pearl pigments. These pigments can be used alone or in combination. The color tone of the intermediate coating can be adjusted by using one or more of these color pigments as appropriate. The average particle size of the color pigment is preferably 2 μm or less, more preferably 0.01 to 1 μm. The average particle size of the pigment is the average value measured using a laser diffraction particle size distribution analyzer (measurement temperature: 25°C).

In addition to the components mentioned above, the intermediate coating material may contain, for example, extender pigments, dyes, aggregates, color particles, matting agents, thickeners, wetting agents, leveling agents, antifreeze agents, film-forming agents, preservatives, antifungal agents, anti-algae agents, antibacterial agents, dispersants, surfactants, defoamers, UV absorbers, light stabilizers, antioxidants, adhesion promoters, stain-reducing agents, hydrophilizing agents, water repellents, crosslinking agents, curing agents, hardening accelerators, plasticizers, coupling agents, adsorbents, pH adjusters, catalysts, water, solvents, etc. The intermediate coating material can be manufactured by uniformly mixing these components using conventional methods.

The pigment volume concentration (PVC) of the intermediate coating material is preferably 50% or less, more preferably 30% or less, even more preferably 5-28%, and especially preferably 8-25%. The use of such an intermediate coating material is advantageous in terms of its ability to conform to the substrate (such as its ability to conform to wall surfaces with joints filled with sealant, etc.) and its ability to create a finish that makes use of the texture of the coated surface. The pigment volume concentration is the volume percentage of the pigment contained in the dried coating, and is a value calculated from the mixed amounts of resin and pigment that make up the intermediate coating material. The specific gravity of the resin is assumed to be 1.

Known methods can be used to apply the intermediate coating material. Possible application methods include, for example, spray coating, roller coating, and brush coating. When applying by roller, a fibrous roller is preferably used. The amount of intermediate coating material applied is preferably 0.05 to 0.8 kg/m ² , more preferably 0.1 to 0.6 kg/m ² . Viscosity can also be adjusted appropriately by adding a diluent such as water during application. The intermediate coating material is preferably dried at room temperature (0 to 40°C). When the intermediate coating material has been applied, the top coating material can be applied after the intermediate coating film has dried.

When applying the primer coat, the entire wall surface can be painted with one type (one color) of primer coat, or two or more primer coats with different color tones can be used. In the latter case, for example, a multi-color pattern combining two or more colors can be created by applying a first primer coat to the entire surface and then selectively applying a second primer coat (a different color from the first primer coat), or by applying the first and second primer coats to specific areas. In this invention, applying such primer coats allows for the desired color to be applied to the surface while also making use of the texture of the surface.

The intermediate coating film formed by applying the intermediate coating may be either glossy or matte (including 70% gloss, 50% gloss, 30% gloss, etc.).

In this invention, a topcoat material is applied to a wall surface as described above using a roller. The topcoat material in this invention contains a synthetic resin emulsion (m) and specific lightweight colored particles (n) as essential components, and the roller used to apply the topcoat material is a fibrous roller with a specific bristle length. In this invention, by applying this specific topcoat material with a specific roller, it is possible to form a uniform speckled pattern. The final finished appearance is a background color (the color of the surface before the topcoat is applied; if an intermediate coat is applied, the color of the intermediate coat film), with a speckled pattern created by the lightweight colored particles (n), resulting in excellent design.

Among the components that make up the topcoat material, synthetic resin emulsion (m) (hereinafter referred to as "component (m)") acts as a binder. Component (m) can be one that forms a transparent coating. Specific examples of component (m) include vinyl acetate resin emulsion, epoxy resin emulsion, acrylic resin emulsion, urethane resin emulsion, acrylic silicone resin emulsion, fluororesin emulsion, etc., as well as composite resin emulsions of these. Among these, acrylic resin emulsion, urethane resin emulsion, acrylic silicone resin emulsion, fluororesin emulsion, etc., as well as composite resin emulsions of these, are preferred from the standpoint of weather resistance, etc. These components (m) can be used alone or in combination, and two or more components (m) can also be mixed. Component (m) may also be crosslinkable.

Component (m) can be produced, for example, by a single-stage or multi-stage (two-stage, three-stage, or more) emulsion polymerization method. When multi-stage emulsion polymerization is used, for example, a multilayer structure emulsion (such as a core-shell emulsion) can be obtained.

The average particle size of component (m) is preferably 30 to 500 nm, more preferably 50 to 300 nm. The average particle size of component (m) can be measured using a dynamic light scattering measurement device (measurement temperature: 25°C). The glass transition temperature of the resin that makes up component (m) is preferably -30 to 80°C, more preferably -20 to 60°C. The glass transition temperature can be calculated using the Fox formula.

The lightweight colored particles (n) (hereinafter referred to as "component (n)") used in the topcoat material must have a bulk density of 1.0 g/ml or less and an average particle diameter of 0.01 to 1 mm. One or more types of lightweight colored particles that meet these conditions can be used as component (n).

The bulk density of component (n) 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. Having a bulk density of component (n) within the above range enables the formation of a uniform speckled pattern, which is also advantageous in terms of coating workability. If the bulk density of component (n) exceeds the above upper limit, the particles are likely to clump together on the surface to be coated during roller coating, which may result in uneven speckled patterns. The bulk density in this invention is measured by supplying lightweight colored particles to a cylindrical container and applying up-and-down vibration (tapping vibration) until the bulk change of the lightweight colored particles in the container is complete.

The average particle size of component (n) is 0.01 to 1 mm, preferably 0.02 to 0.5 mm, and more preferably 0.03 to 0.3 mm. Having an average particle size of component (n) within the above range makes it possible to form a uniform speckled pattern, which is also advantageous in terms of paint workability, etc. If the average particle size of component (n) is smaller than the above lower limit, the speckled pattern will be difficult to discern on the finished surface after painting. If the average particle size of component (n) is larger than the above upper limit, particles will clump together or have convex shapes, which will be disadvantageous in terms of finish and aesthetics, etc. There is also a risk of reduced paint workability.

The shape of component (n) is not particularly limited, but in the present invention, granular components are preferred. "Granular" here refers to a shape in which the average particle diameter and average thickness are similar. Specifically, component (n) with a ratio of average particle diameter to average thickness (average particle diameter/average thickness) of 2 or less (preferably 1.5 or less) is preferred. Using components with such a shape is even more advantageous in terms of homogenizing the speckled pattern and can improve the aesthetic appeal of the formed coating.

The average particle size of component (n) is the average long diameter when particles placed on a horizontal surface in the most stable position are observed from above. The average thickness is the average interplanar spacing when particles placed on a horizontal surface in the most stable position are sandwiched between two horizontal surfaces.

It is desirable that the (n) component in the topcoat contains a color that is different from the background color before the topcoat is applied. This allows the speckled pattern caused by the (n) component to be clearly visible on the finished surface after painting. If two or more intermediate coats are used to apply different colors before the topcoat is applied, the color tone of the (n) component should be a different color from at least one of the intermediate coats.

In the present invention, "different colors" refers to colors that can be visually recognized as different from each other. 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 measured using a colorimeter. For particles such as component (n), particles are placed on a glass plate until the glass surface is hidden, and the surface covered with a PE film (colorless and transparent) is measured.

Component (n) can be, for example, a material based on rubber, resin, mineral, wood, plant, etc., with organic particles based on rubber or resin being particularly suitable. The internal structure of such component (n) is not particularly limited, as long as the bulk density, average particle size, etc., satisfy the above-mentioned conditions, and examples include solid, foamed, and porous bodies. The color tone of component (n) can be, for example, the original color tone of the matrix, or can be imparted by subjecting the matrix to a coloring treatment (e.g., coloring the interior of the matrix, coloring the surface of the matrix, etc.).

The amount of component (n) mixed is 0.1 to 50 parts by weight, preferably 0.5 to 30 parts by weight, and more preferably 1 to 20 parts by weight, per 100 parts by weight of the solids content of component (m). Keeping the amount of component (n) within this range makes it possible to form a highly aesthetic, uniform spotted pattern in which spots are imparted to the background color. If the amount of component (n) mixed exceeds the above upper limit, the spotted pattern is likely to become uneven and the background color of the underlying layer is likely to be concealed, which is disadvantageous in terms of spotted pattern formation. If the amount of component (n) mixed is less than the above lower limit, the spotted pattern will be difficult to discern on the finished surface after painting.

The topcoat material may contain at least one type (one color) of lightweight colored particles, or may contain two or more types of lightweight colored particles with different color tones.

The topcoat material may contain, within the scope of the present invention's intended effects, for example, color pigments, extender pigments, dyes, matting agents, thickeners, wetting agents, leveling agents, antifreeze agents, film-forming aids, preservatives, antifungal agents, anti-algae agents, antibacterial agents, dispersants, surfactants, defoamers, UV absorbers, light stabilizers, antioxidants, adhesion promoters, stain-reducing agents, hydrophilizing agents, water repellents, crosslinking agents, curing agents, curing accelerators, plasticizers, coupling agents, adsorbents, pH adjusters, catalysts, water, solvents, etc. The topcoat material can be manufactured by uniformly mixing these components using conventional methods.

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 in accordance with the method specified in JIS K5601-1-2 "Heating Residue" (heating temperature: 135°C, heating time: 60 minutes).

The coating formed by the topcoat material is a transparent coating in which component (n) is dispersed, creating a speckled pattern. In other words, it has a transparency that allows the background color before the topcoat material is applied to be visible. The transparent coating formed by the topcoat material may be either colorless and transparent or colored and transparent, and may be glossy or matte (including 70% gloss, 50% gloss, 30% gloss, etc.). Of these, colored and transparent coatings can be formed, for example, using topcoats containing color pigments, dyes, etc., and the degree of coloring can be set within a range that allows the background color and speckled pattern to be visible. Matte coatings can be formed, for example, using topcoats containing extender pigments, matting agents, etc.

The topcoat material of the present invention is different from materials known as multicolor pattern paints (multicolor paints), stone-look finish coatings (stone-look paints), etc. Generally, multicolor pattern paints contain a high proportion of liquid or gel-like color particles, which form a multicolored pattern, while stone-look finish coatings contain a high proportion of colored aggregates or natural aggregates, which produce a stone-look texture through the coloring of these aggregates. In contrast, the topcoat material of the present invention, as configured as described above, forms a speckled pattern dotted with lightweight colored particles (n). The main color is expressed by the background color.

In the present invention, the above-mentioned topcoat material is applied by roller coating using a fibrous roller with a bristle length of 10 mm or more. This makes it possible to form a uniform speckled pattern. The reasons for this effect are not limited to the following, but it is thought that the lightweight colored particles (n) contained in the topcoat material are light and small, making them easy to disperse, and that the long fibers of the fibrous roller sufficiently promote the dispersion of these lightweight colored particles (n) during roller coating, thereby forming a uniform speckled pattern.

An example of a fibrous roller used in the present invention is shown in Figure 1. The fibrous roller in Figure 1 has a fibrous layer on the outer surface of a cylindrical core material. The cylindrical core material is hollow so that a handle with a shaft can be attached, and the handle can be attached to the hollow and used. The cylindrical core material can be made of, for example, plastic, wood, metal, or paper. Furthermore, to improve the ease of attachment between the handle shaft and the core material, an attachment aid or the like can be provided between the handle shaft 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.

The fibrous roller used in the present invention has a bristle length of 10 mm or more, preferably 12 mm or more, more preferably 15 to 40 mm, even more preferably 18 to 38 mm, and particularly preferably 20 to 36 mm. Bristle length refers to the length of the fibers that make up the fibrous roller. Specifically, bristle length can be determined by lightly pinching the fibers of a dry fibrous roller with your fingers and stretching them outward from the core, measuring the fiber length, and calculating the average value. In the present invention, a fibrous roller with such a bristle length can be used to apply a topcoat material, thereby forming a uniform spotted pattern. If the bristle length of the fibrous roller is less than the above-mentioned lower limit, it will be difficult to form a uniform spotted pattern.

Examples of the fiber material that makes up the fibrous layer include pig hair, horse hair, goat hair, sheep hair, raccoon hair, human hair, silk, cotton, etc., as well as synthetic fibers such as acrylic fiber, polyurethane fiber, polyester fiber, and polypropylene fiber. The fibrous layer can be formed by knitting or weaving an assembly of such fibers (for example, cotton-like pile, thread-like pile, etc.).

When applying a topcoat material using such a fibrous roller, the viscosity of the topcoat material can be set appropriately. The topcoat material to be applied can be diluted with water, etc., as necessary. The viscosity of the topcoat material (when applied) is preferably 0.1 to 15 Pa·s, more preferably 0.3 to 13 Pa·s. The thixotropy index of the topcoat material (when applied) is preferably 6 or less, more preferably 1 to 5. The viscosity is determined by measuring the viscosity at 20 rpm (the guideline value at the fourth rotation) using a BH-type viscometer. The thixotropy index (TI) is a value determined using the following formula using a BH-type viscometer. The measurement temperature in both cases is 23°C.
<Formula>TI=η1/η2
(where η1 is the viscosity at 2 rpm (Pa·s: indicator value at the second rotation), and η2 is the viscosity at 20 rpm (Pa·s: indicator value at the fourth rotation))

The topcoat material in the present invention can be applied to the entire wall surface. The amount of topcoat material applied 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 coats of the topcoat material is preferably 1 to 2 times, more preferably 1 time. By applying the topcoat material under these conditions, a relatively thick film is formed, which further promotes the dispersion of the lightweight colored particles (n), and is more advantageous in terms of forming a uniform spotted pattern.

After applying the topcoat, drying should preferably be carried out at room temperature (0-40°C). Drying time is preferably at least 1 hour, and preferably 2-24 hours.

In the present invention, the coating formation method described above can enhance the aesthetic appeal of existing wall surfaces at construction sites, etc. The present invention is suitable for repairing (refurbishing) such wall surfaces. By applying the coating formation method of the present invention to wall surfaces that have deteriorated over time, the aesthetic appeal of the wall surface can be improved, and it is possible to restore the color to that of the original construction, or to impart a new color different from that of the original construction. For wall surfaces made of inorganic building materials such as siding boards or ALC panels, and having joints where the inorganic building materials are joined together filled with a sealant or the like, the method of the present invention can also be applied to the entire surface, including the inorganic building materials and the joints.

The following examples and comparative examples will clarify the features of the present invention. However, the present invention is not limited to these examples.

The following topcoat materials were prepared:
・Top coating material 1
Synthetic resin emulsion a (acrylic silicone resin emulsion, solids content 50 wt%, glass transition temperature 32 ° C, average particle diameter 110 nm) 200 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) 4 parts by weight, 12 parts by weight of film-forming aid, 1 part by weight of ultraviolet absorber, 2 parts by weight of viscosity adjuster, 3 parts by weight of antifoaming agent were mixed, and further water was mixed to prepare a heating residue of 40 wt%, to obtain topcoat material 1.

・Top coating material 2
200 parts by weight of synthetic resin emulsion b (acrylic resin emulsion, solids 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 film-forming aid, 2 parts by weight of viscosity adjuster, 3 parts by weight of antifoaming agent were mixed, and further water was mixed to prepare a heating residue of 45% by weight, thereby obtaining topcoat material 2.

・Top coating material 3
200 parts by weight of synthetic resin emulsion c (acrylic silicone resin emulsion, solids 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 film-forming aid, 1 part by weight of ultraviolet absorber, 2 parts by weight of viscosity adjuster, 3 parts by weight of antifoaming agent were mixed, and further water was mixed to prepare a heating residue of 42% by weight, thereby obtaining topcoat material 3.

・Top coating material 4
In the above-mentioned topcoat material 1, topcoat material 4 was obtained in the same manner as topcoat material 1, except that the mixed amount of lightweight colored particles a was 12 parts by weight.

・Top coating material 5
In the above-mentioned topcoat material 1, topcoat material 5 was obtained in the same manner as topcoat material 1, except that the mixed amount of lightweight colored particles a was 32 parts by weight.

・Top coating material 6
In the above-mentioned topcoat material 1, instead of the lightweight colored particles a, 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 4 parts by weight, except that topcoat material 6 was obtained in the same manner as topcoat material 1.

・Top coating material 7
In the above-mentioned topcoat material 1, instead of the lightweight colored particles a, black mica (bulk density 0.40 g / ml, average particle diameter 0.12 mm, average particle diameter / average thickness = 28) was mixed in 4 parts by weight, except that topcoat material 7 was obtained in the same manner as topcoat material 1.

・Top coating material 8
For 200 parts by weight of synthetic resin emulsion a (same as above), 4 parts by weight of lightweight colored particles d (white resin particles, bulk density 0.72 g / ml, average particle diameter 0.1 mm, average particle diameter / average thickness = 1.0), 12 parts by weight of film-forming aid, 50 parts by weight of matting agent (uncolored resin particles, average particle diameter 15 μm), 1 part by weight of ultraviolet absorber, 2 parts by weight of viscosity adjuster, 3 parts by weight of antifoaming agent were mixed, and water was further added to adjust the heating residue to 40% by weight, thereby obtaining topcoat material 8.

・Top coating material 9
200 parts by weight of synthetic resin emulsion a (same as above) were mixed with 2 parts by weight of lightweight colored particles a (same as above), 2 parts by weight of lightweight colored particles d (same as above), 12 parts by weight of film-forming agent, 50 parts by weight of matting agent (same as above), 1 part by weight of ultraviolet absorber, 2 parts by weight of viscosity adjuster, and 3 parts by weight of antifoaming agent, and then water was added to adjust the heating residue to 40% by weight, thereby obtaining topcoat material 9.

The following rollers were prepared:
Roller 1 (fiber roller (wool roller), bristle length 25 mm)
Roller 2 (fiber roller (wool roller), bristle length 32 mm)
Roller 3 (fiber roller (wool roller), bristle length 21 mm)
Roller 4 (fiber roller (wool roller), bristle length 13 mm)
Roller 5 (fiber roller (wool roller), bristle length 7 mm)

Example 1
For flat slate boards, primer material A (aqueous epoxy sealer) was spray-painted on the entire surface at a coating amount of 100 g / m ² , and after drying for 24 hours, intermediate coating material A (light gray glossy synthetic resin emulsion paint, acrylic resin system) was spray-painted on the entire surface at a coating amount of 150 g / m ² , and after drying for 2 hours, intermediate coating material A was spray-painted on the entire surface again at a coating amount of 150 g / m ² and dried for 24 hours. Next, using roller 1, top coating material 1 was roller-painted on the entire surface at a coating amount of 120 g / m ² and dried for 24 hours. All of the above processes were carried out under standard conditions (temperature 23 ° C, relative humidity 50%). The color difference between the black resin particles and intermediate coating material A was 50.

The finish of the test specimens obtained using the above method was visually evaluated. The evaluation criteria were a four-point scale (excellent: A > B > C > D: poor), with "A" indicating a uniform speckled pattern formed by the colored particles and "D" indicating a finish in which the speckled pattern was noticeably uneven due to clumping of the colored particles. The results are shown in Table 1.

(Examples 2 to 9, Comparative Examples 1 to 3)
Except for using the roller and topcoat material described in Table 1 instead of roller 1 and topcoat material 1, test specimens were prepared in the same manner as in Example 1, and the finish was evaluated. The results are shown in Table 1.

Example 10
For ceramic siding boards with a brick-like uneven pattern, primer b (aqueous epoxy surfacer) was spray-painted on the entire surface at a coating amount of 200 g / m ² , and after drying for 3 hours, intermediate coating b (black glossy synthetic resin emulsion paint, acrylic silicone resin system) was spray-painted on the entire surface at a coating amount of 150 g / m ² , and after drying for 2 hours, intermediate coating b was again spray-painted on the entire surface at a coating amount of 150 g / m ² and dried for 2 hours. Then, using roller 5, intermediate coating c (brown glossy synthetic resin emulsion paint, acrylic silicone resin system) was partially painted (coating amount 60 g / m ² ) and dried for 24 hours. Next, using roller 1, top coating material 8 was roller-painted on the entire surface at a coating amount of 180 g / m ² and dried for 24 hours. All of the above processes were carried out under standard conditions (temperature 23 ° C, relative humidity 50%). The color difference between the white resin particles and intermediate coating material b was 67, and the color difference between the white resin particles and intermediate coating material c was 51.

The test specimens obtained using the above method were evaluated for finish. The evaluation criteria were as described above. The results are shown in Table 2.

Example 11
Except for using topcoat material 9 instead of topcoat material 8, a test specimen was prepared in the same manner as in Example 10, and the finish was evaluated. The results are shown in Table 2. The color difference between the white resin particles and intermediate coating material b was 67, the color difference between the white resin particles and intermediate coating material c was 51, the color difference between the black resin particles and intermediate coating material b was 2, and the color difference between the black resin particles and intermediate coating material c was 17.

(Examples 12 to 14, Comparative Example 4)
Except for using the roller 1 and the topcoat material 8 instead of the roller and the topcoat material described in Table 2, a test specimen was prepared in the same manner as in Example 10, and the finish was evaluated. The results are shown in Table 2.

Claims (2)

A coating forming method for roller coating a topcoat material on a wall surface,
As the topcoat material, synthetic resin emulsion (m), and bulk density is 1.0 g / ml or less, average particle diameter is 0.01 to 1 mm, average particle diameter and average thickness ratio is 1.0 to 1.5 granular lightweight colored particles (n) are essential components, and the synthetic resin emulsion (m) solids 100 parts by weight, the granular lightweight colored particles (n) are used to contain 0.1 to 50 parts by weight of the topcoat material,
A coating forming method characterized in that a fibrous roller having a bristle length of 18 to 38 mm is used as the roller . The coating forming method according to claim 1, characterized in that after applying a primer and/or intermediate coating material to a wall surface, the topcoat material is applied by roller coating.